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Lincoln Electric PRO-CUT SVM146-A User's Manual

1. iy L Ee Ee EES IS pr Lech HEHM STOR P OHMS 400MA CAPACITORS MFD VOLTS RESISTORS OHMS o o olo Fir ci o o s 8 2 eli 515 ply oO el ies G 3439 1 Return to Section TOC Return to Master TOC NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the LINCOLN E machine PRO CUT 80 SCH ELECTRICAL DIAGRAMS G 10 SCHEMATIC DISPLAY PC BOARD 5 READY SIGNAL HLMP 2855 Return to Master TOC Return to Section TOC HLMP 2550 m e CONTROL POT AIR LOW SIGNAL HLMP 2350 HLMP 2655 Return to Section TOC Return to Master TOC HLMP 2755
2. SAFETY RESET 052 10p 100V MODB IRQ X q AIR SOLENOID XTAL D jer X5 THERMOSTAT OK CONTROL POT PURGE SAFETY RESET PSI OK PRIMARY VOLTAGE IGBT DRIVE 3ODE AMPS RETRACT ARC TACH INPUT TACH INPUT Return to Section TOC Return to Master TOC SENSE AMPS PRIMARY POWER OUTPUT 7 1 PW BOARD 0k TRANSFER SHUNT gt gt AIR LOW J2 gt gt 0 A B Irene 2700p 50V ELECTRODE_AMPS POWER SUPPLY 0 0 lm MACHINE OVERVIEW o o olo Fir ei o o s 8 2 SS LE 515 ply olo c a 10 0K GENERAL INFORMATION SPECIFIED 20 LABELS A SUPPLY VOLTAGE NET Q POWER SUPPLY SOURCE POINT S7 COMMON CONNECTION 471 2 FRAME CONNECTION EARTH GROUND CONN ON A PRINTED CIRCUIT BOARD MAY CHA BILITY OF P IS DIAGRAM MAY ENT
3. ojo ds 6 S OUTPUT CONNECTIONS FIGURE A 4 TORCH CONNECTION 9 AT CASE ole TORCH CONNECTION Gas 8 9 Status Reset Purge Gas cle The PRO CUT 80 is supplied from the factory with a Indicators Putton Button Regulator 3 E PCT 80 cutting torch Additional cutting torches can Gauge e d be ordered from the K1571 series Hand held and mechanized torches come with 25 or 50 foot cables Output Gas All torches are connected to the Pro Cut with a quick 7 connect at the case front for easy change over See Figure A 4 Consumable For more information on the torch and its components ahi refer to the PCT 80 Operator s Manual IM595 door e Input Fle Power zin Toren Switch B 2 Connector Work Q 5 Cable Interface o Connector 2 2 EIE 313 Pc Oo o Ee s s im Qis o s 8 2 EIE 312 dc ojo ds 5 8 Qis o ix als SIE 513 Dlo HK PRO CUT 80 LINCOLN 5 Section B 1 Section B 1 TABLE OF CONTENTS o 2 OPERATION SECTION 2 Operation tenter deter bs b s Section B 5 Eeleren EE B 2 General Description TEE B 3 E Recommended Process and Eouipment ee B 3 Operational Features and Controls EEN B 3 Design Features and AdVantages cccceceeecceeeeeeeeceeceeseeeeeeeeseeeeeeeessaeeeesesseeeseeeneeseeeeseneeeeees B 3 GUNNO Nee ET UE B 4 Consumable ce EE B 4 lucc ese B 4 a RE
4. Dee Sub ed Sege R LSR Lela A 7 OUTPUT COMMECTIONS sueco aad Raya araya A 8 Torch Conpechon ENEE A 8 o o E E o iyi o c x E o Return to Master PRO CUT 80 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC olo olo Fle 515 om Hie o lx 88 l olo cc a Return to Section TOC Return to Master TOC Return to Master TOC INSTALLATION TECHNICAL SPECIFICATIONS PRO CUT 80 INPUT RATINGS Single Phase Input Input Currents Rated Output Amps Voltage and Hertz 208 1 60 230 1 60 460 1 60 Three Phase Input Input Currents Rated Output Amps Voltage and Hertz 208 3 60 230 3 60 460 3 60 IDLE CURRENT AND WATTS 230 1 60 0 61 Amps 140 Watts RATED OUTPUT Duty Cycle Rated Output Amps 6096 10096 OUTPUT Current Range Open Circuit Voltage Pilot Current 35 85 Amps 335VDC Maximum 20 Amps 100 Duty Cycle PRO CUT 80 LINCOLN A 3 A 3 INSTALLATION TECHNICAL SPECIFICATIONS Cont d PRO CUT 80 GAS REQUIREMENTS Required Gas Flow Rate Required Gas Inlet Pressure 70 PSI 480 SCHF 80 to 150 PSI 4 8 Bar 13550 LHR 5 4 Bar to 10 2 Bar Return to Section TOC Return to Master TOC RECOMMENDED INPUT WIRE AND FUSE SIZES For all plasma cutting applications based on U S National Electrical Code Ambient Temperature 30
5. n OUTPUT PC BOARD SCHEMATIC o s ln lk s sl 2 OUTPUT PC BOARD ASSEMBLY 88 00202 DISPLAY PC BOARD SCHEMATIC RR DISPLAY PC BOARD ASSEMBLY e 8 62 PRO CUT 80 LINCOLN P G 1 G 2 ELECTRICAL DIAGRAMS ETE 6 2 WIRING DIAGRAM PRO CUT 80 RIGHT SIDE OF MACHINE mA 1 8 en 8 53 N C3 56 CT 24V R X66 54 LI 18V U lt X9 64 WAS 8 mm 62 lt 4 Return to Section TOC Return to Master TOC 7 ue U X4 61 J22 my Y 1 FAN LU r 7 FAN VOLT AUXILIARY J21 P XFMR TRANSFORMER LOW_PSI LED CURRENT TRANSFORMER 550 THERMAL LED RESET LED C2 3000 450 3000 4 J33 A ELEC FER FRONT OF MACHINE Ta is Return to Section TOC Return to Master TOC x ptg L D Xe CONTROL OO POT G a 2 GND CW MAX deeg Hi 60 i T 2 6 PSI SWITCH E 10 ELEC SOL l LI LI REAR OF MACHINE 9 AIR SOL SHOWN FOR 400 460VAC OPERATION b sos S0 I an CONTROL GE elo olo Fle E s ois o ls SIS l olo c a ES SUPPLIED WITH INPUT CABLE ASE INPUT CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE LEFT SIDE OF MACHINE E PLY CIRCUIT COLOR CODE TH TAPE TO PROVIDE 600V INSULATION B BLACK PUT CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE Q G GREEN m
6. azon e 100 28 100 H v3 er l pjeoq uo pjeoq uo uo OX p l qe 02X pejeqe1 pejeqe 1 Don uo px palage 300419313 BTZON CSC 767 aM a HENHO SNYEL NIVW SCHEMATIC OUTPUT PC BOARD LINCOLN E G 8 OOL 1SEIN 0 1 SOL uonoeg oj uanjeH OOL 1SPIN 0 uunjeH Uuonoesg o uanjeH DOL 1SPIN 0 1 OOL uonoesg o uanjeH DOL 19 SeW 0 1 OOL uonoeg o G ELECTRICAL DIAGRAMS e PC BOARD ASSEMBLY OUTPUT BOARD OO TEM 1 X C1 C3 C11 C15 C34 035 ra E 5 0015 2000V C2 ss C20 022 023 024 029 038 MG ESE 022 50 Ces Return to Section TOC Return to Master TOC G3439 1 OUTPUT D10 D11 D13 D14 D15 D16 D17 D19 D20 D21 D23 D25 ES Hs BL 1 4 GE Jet e LE m br rr TF Em E EE A R3 R4 300 66 SW OHM PWH H OR Return to Section Return to Master TOC
7. 22147 082 Vortech nozzle with an 082 2 1 mm Orifice For Gouging at 60 85 Amps S22149 Electrode replacement electrodes for cut ting 22150 Shield Cup This shields the torch tip and provides more visibility to the workpiece than the drag cup Note the shield cup does not prevent the torch tip from touching the workpiece S22151 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 80 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 PRO CUT 80 LINCOLN 5 Section D 1 Section D 1 TABLE OF CONTENTS MAINTENANCE Maintenance m Section D E UE D 2 Input Filter Capacitor Discharge Procedure EEN D 2 Routine Maintenance D 3 Return to Master TOC Periodic Maintenance D 3 Major Component LocatlOris 4 Return to Master o o FE E E o o c x E o Return to Master PRO CUT 80 LINCOLN 5 Return to Section TOC Return t
8. 4 Garder tous les couvercles et dispostifis de s ret leur place PRO CUT 80 LINCOLN 5 MASTER TABLE OF CONTENTS FOR ALL SECTIONS RETURN TO MAIN INDEX Page Safety ine 0000000000 00000 00 i iv E UE e TER Section A Technical Specifications EE A 2 3 oalety e EE A 4 Select Suitable Location a aa 0 0000077777 A 4 SE 9118101250 0 A 4 Ling and Moving ET A 4 RI e DEE A 4 High Frequency Interference Protection ALAR RRReRe eee nem A 4 Input Electrical Connections AEN A 5 Input Power Cord Connector Installation A A 5 Frame GrOUNGING e m A 5 Gas Input Conpnectlons nennen enhn nin aR A ARA AAA ARAR YR haad Siaga aaa aila A 7 OUTPUT Connections iecore imei Rud ARAYA B BAR e da nena Pap ER UR TRA te eee ee E Rv ead A 8 cup me end Section B ld Precautions ERE B 2 General DescriptiODn eceo an aaa haza EE Edge B 3 Recommended Processes and Equipment essere nnn B 3 Operational Features and Controls ced SERERE AAEREN B 3 Design Features and Advantages ince g rupe ot EE ERR B 3 Cutting ee B 4 TE EI Nj tet B 4 acu clc Ea B 4 Controls and E ne ie ORE B 5 Pilot Are DISCUSSION EE B 5 ld eeler Le E B 5 UseriResporisiDIlILy ey iy Preheat T
9. The gas will immediately turn off The pressure gauge may show an increase in pressure after the air turns off but this is normal Do NOT reset the pres sure while the air is NOT flowing When ready to cut place the torch near the work make certain all safety precautions have been taken and 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 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 3 2mm to 3 16 in
10. 4 7mm above the vvorkpiece during cutting Do not let the torch nozzle touch the vvork 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 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 Direction of Travel Y d 10 20 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 f the dross is difficult to remove reduce the cutting speed High speed dross is more difficult to remove than low speed dross e 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 3 2mm to 3 16 4 7mm above the workpiece ANGLE OF APPROACH Ke HELD AT V 45 ANGLE 1 THROUGHOUT GOUGE il ANGL MAINTAINED THROUGHOUT
11. IET esse a S a g RI E g 59 a a 2 x dl E a a A co a STI 2 Return to Section TOC Return to Master TOC R38 R39 S19400 30R1 S19400 6190 1 S19400 8251 8 7 R190 R191 R193 R194 5 519401 8 1 S19400 2001 R9 R15 R50 R64 R88 R103 7 519401 R113 10 R42 R96 3 519400 5110 11 R12 R13 R14 4 S19400 332 16 R2 2 19400 332 7 R2 62 31 19 EJ x z 5 EJ ES l E isi 5 EI Si gt EI RS P E zi cl 219 KSE R63 R68 R69 R81 R84 R93 R94 R104 R106 R108 R134 R138 R139 R154 R156 R158 R160 R164 R165 R166 R178 R179 R180 R181 R182 qUK 1 4 R20 R22 R110 R111 R124 12 19400H R125 R126 R127 R128 R142 R196 R197 24 R35 2 519400 2210 221 1 4 H25 R4 R49 R80 R89 H153 1 9194001008 pOK 1 4W R183 R28 R112 R115 R116 R117 7 S19400 3321 32K 1 4W R118 R133 SE 10400 8 825 17 10400 1004 N77 1 51900 6191 1 Ep c l S 5j RE E z x ES x 6 R41 R60 R135 R184 43 R44 R45 R130 R Ex as m 5 E RI ag e RE of o3 o o E o iyi o 2 E x 3 o 48 1L S19400 2802 18 0K 1 4 52 R54 R56 3 519400 10 58 R76 RO9 RT00 1 819400 7 65 RT20 2 519400 221 67 R70 RET RTOT 1 519400 72 RT95 S19400 15 T3 RT07 19400 768 77 R82 RT75 R17 7 519400 13D1 L3 1 4W 78 RT59 2 ST9400 T2TT REISE D 79 R83 RT55 R167 S1
12. Volt Ohmmeter Multimeter 5 16 Nut driver Insulated gloves Insulated pliers High wattage resistor 25 to 1000 ohms 25 watts minimum This procedure takes approximately 10 minutes to perform PRO CUT 80 LINCOLN 5 F 10 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o E o o O o 8 E 3 E o Return to Section TOC Return to Master TOC o o E E o iyi o x 5 o 11 TROUBLESHOOTING 8 REPAIR A WARNING ELECTRIC SHOCK can kill e Have an electrician install and service this equipment e Turn the input power off at the fuse box before vvorking on equipment Do not touch electrically hot parts 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 at the bottom of the Input Power Board INPUT FILTER CAPACITOR DISCHARGE PROCEDURE continued 4 Obtain a high resistance and high wattage resistor 25 1000 ohms and 25 watts mini mum This resistor is not supplied with machine NEVER USE A SHORTING STRAP FOR THIS PROCEDURE Locate the four capacitor terminals large hex
13. Torch Continui and Solenoid Test The control board may be faulty Replace If the machine operates normal ly with the Safety LED on the display board may be faulty Replace A CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 PRO CUT 80 LINCOLN 5 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 Return to Section TOC Return to Master TOC The Thermal LED is lit One of the machine s ther 1 A thermostat may be faulty mostats has tripped Do not Replace turn the PRO CUT 80 off Allow the machine to cool The ther mostat s will reset themselves The control board may be faulty Replace If the machine operates normal ly with the Thermal LED lit the display board may be faulty Replace Either the duty cycle has been exceeded the fan is not func tioning or the louvers are blocked Return to Section TOC Return to Master TOC olo O o E 515 om PEN iz 818 olo cc a A CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repa
14. trical shock please observe all safety notes and precautions detailed throughout this manu al Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION This procedure will help the technician determine if the solenoid is functioning properly Return to Section TOC Return to Master TOC MATERIALS NEEDED 5 16 Nut driver 12 VDC 3 amp supply Volt ohmmeter This procedure takes approximately 13 minutes to perform olo olo E 515 45 0 Hie iz 818 cc a Return to Section TOC Return to Master TOC PRO CUT 80 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o amp o o O o 8 E 3 E o Return to Section TOC Return to Master TOC o o FE E o iyi o x 5 o 26 26 TROUBLESHOOTING 8 REPAIR AIR GAS SOLENOID TEST continued FIGURE F 6 AIR SOLENOID TEST PROCEDURE 1 2 3 Remove input power to the machine Perform the Input Capacitor Discharge Procedure detailed earlier in this section Locate the air solenoid and leads See Figure F 6 Carefully remove plug J31 from the outpu
15. vide des deux machines 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 Un coup d arc peut tre plus s v re qu un coup de soliel donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du rayonnement de l arc et des projections quand on soude ou quand on regarde l arc b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnementde l arc c Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflamma bles 4 Des gouttes de laiter en fusion sont mises de l arc de soudage Se prot ger avec es v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes 5 Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec 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 7 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 8 S assurer que la masse est connect
16. LINCOLN E Return to Section TOC Return to Master TOC Return to Section TOC olo O o E 515 om PEN iz 818 olo cc a Return to Section TOC Return to Master TOC Return to Master TOC B 4 B 4 OPERATION CUTTING CAPABILITY The PRO CUT 80 is rated at 80 amps at 6096 duty cycle on a 10 minute basis or 60 amps at 10096 duty cycle If the duty cycle is exceeded a thermal protec tor will shut off the output of the machine until it cools to the normal operating temperature Figure B 1 shows the cut capacity of the PRO CUT 80 when cutting mild steel The graph plots cut thickness vs torch travel speed with a torch standoff of 0 15 in 3 8mm Example 0 5 material Amps Speed IPM 55 25 80 35 FIGURE B 1 LINCOLN S PRO CUT 80 MILD STEEL CUT CAPACITY CHART Lincoln s PRO CUT 80 Mild Steel Cut Capacity Chart 100 CO o 60 40 8096 of Maximum Speed 20 25A Recommended Torch Travel Speed IPM 35 A 55 A 80 A 0 0 000 0 125 0 250 0 375 0 500 0 625 0 750 1 00 Material Thickness CONSUMABLE LIFE The expected life for the PRO CUT 80 s electrode under normal operating conditions is approximately 160 starts cuts An erosion of 060 in 1 5mm is typ ical for end of electrode life However the electrode may last longer A green and erratic arc will indicate definite electrode failure and the electrode sh
17. R3 R4 R7 R8 R11 R12 6 1519400 1000 1100 1 2W 75 1 4W Return to Section TOC Return to Master TOC o o olo Fir ci o o s 8 2 SS LE 515 ply olo c a Return to Section TOC Return to Master TOC NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the LINCOLN E ine LINCOLN Y maghing PRO CUT 80 Return to Master TOC Return to Master TOC o o E o E o iyi o x E o Return to Master SVM ERROR REPORTING FORM VVe need to knovv if there are errors in our manuals VVe also value any suggestions as to additional tests or procedures that vvould make this SVM a better tool for you If you discover new or different Problems or Symptoms that are not covered in the three col umn troubleshooting chart please share this information with us Please include the machine s code number and how the problem was resolved Thank You Technical Services Group
18. drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c PRO CUT 80 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 re
19. insulating gloves Turn the 80 Power Switch OFF when connecting power cord to input power Only qualified personnel should install use or ser vice this equipment SELECT SUITABLE LOCATION Place the PRO CUT 80 where clean cool air can freely circulate in through the rear louvers and out through the front bottom opening Dirt dust or any foreign material that can be drawn into the machine should be kept at a minimum Failure to observe these precau tions can result in excessive operating temperatures and nuisance shutdown of the machine A source of clean dry air or nitrogen must be supplied to the PRO CUT 80 Oil in the air is a severe problem and must be avoided The supply pressure must be between 80 and 150 psi The flow rate is approximate ly 6 0 cfm 170 l min Failure to observe these pre cautions could result in excessive operating tempera tures or damage to the torch STACKING The PRO CUT 80 cannot be stacked LIFTING AND MOVING AA VV ARNING 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 designed to support the full weight of the machine Using it to lift the machine could cause per sonal injury or damage to the machine e Either the front or rear handles or both may be used to lift or move the machine TILTING The PRO CUT 80 must be placed on a stable level surface so it will not
20. om PEN o s DAP l olo cc a Return to Section TOC Return to Master TOC PRO CUT 80 LINCOLN 5 F 48 F 48 TROUBLESHOOTING 8 REPAIR OUTPUT POWER BOARD REMOVAL amp REPLACEMENT continued FIGURE F 22 OUTPUT BOARD LEAD LOCATIONS Return to Section TOC Return to Master TOC G3439 PRO CUT 80 OUTPUT TEST POINT D25 Return to Section TOC Return to Master TOC TEST POINT Sch L re 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 J33 and J34 from the output power board A CAUTION 6 Remove leads X20 and X40 from the output power board Be sure to follovv the recommended static free methods for handling printed circuit boards 7 Using the phillips head screvv driver remove Failure to do so can result in permanent damage the four screws from the lower upper left to the equipment and right corners of the output power board olo olo Fle 515 45 0 PEN iz 818 olo cc a 8 Using the 3 16 allen head wrench remove the four socket screws mounting the output power board to the heat sink Return to Section TOC Return to Master TOC PRO CUT 80 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC olo olo E 515 45 0 Hie o lx 818 olo cc a Return to Section TOC Return to Master TOC Return to Mas
21. 0 pd pd E pd i 1 5 4 BR E Return to Section TOC Return to Master TOC NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the LIM N E ine LINCOLN Y maghing PRO CUT 80 Ge ELECTRICAL DIAGRAMS G 6 SCHEMATIC POWER PC BOARD ojo 209 POSITIVE o B209 elo INPUT RECTIFIER Ld 415V D min 2 l t 1
22. 17 VDC from plug J31 pin 1 lead 4 positive See to plug J31 pin 2 lead 2 negative If the correct voltage is not pre sent perform the Low Voltage Circuit Test Also see Output Board LED Definitions and related figures Also see Output Board LED test carefully pull the torch trigger A WARNING PILOT ARC CUTTING ARC AND HIGH VOLT e AGE MAY BE PRESENT AT THE PRO CUT 80 LINCOLN 5 TORCH HEAD Perform this test with the air input removed to avoid a pilot arc at the torch F 32 F 32 TROUBLESHOOTING amp REPAIR TRIGGER CIRCUIT TEST continued 9 With the torch trigger activated check the voltage at plug J32 pin 3 lead 354 posi tive to plug J32 pin 14 lead 312 nega tive Normal is less than 1 VDC If more than 1 VDC is indicated the power output board may be faulty Release deactivate the torch trigger and remove input power to the PRO CUT 80 10 Perform the Input Filter Capacitor Discharge Procedure 11 Check the continuity of leads 354 and 312 between the output board and the control board See the and 12 If all of the above checks are OK the con trol board may be faulty Replace Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo olo Fle 515 xo im Hie o lx 818 olo cc a Return to Section TOC Return to Master TOC PRO CUT 80 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Sect
23. 207 207A and 209 FIGURE F 2 INPUT RECTIFIER AND LEADS a 207 209 TOP VIEW PRO CUT 80 LINCOLN E F 14 F 14 TROUBLESHOOTING 8 REPAIR INPUT RECTIFIER TEST continued TABLE F 1 INPUT RECTIFIER TEST POINTS TEST POINT TERMINALS ANALOG METER X10 RANGE Acceptable Meter Readings Greater than 1000 ohms Greater than 1000 ohms Greater than 1000 ohms Return to Section TOC Return to Master TOC Greater than 1000 ohms Greater than 1000 ohms Greater than 1000 ohms Less than 100 ohms Less than 100 ohms Less than 100 ohms Less than 100 ohms Less than 100 ohms Less than 100 ohms o o o o O o 8 3 o Return to Master Less than 100 ohms Less than 100 ohms Less than 100 ohms Greater than 1000 ohms o o Greater than 1000 ohms S 5 Greater than 1000 ohms 10 olg o s g 2 EIE 812 E E 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 NOTE Before replacing the input rectifier D1 H goatng of com R d pound and Dow Corning 738 Silicone check the input power switch S1 and Sealant perform the Primary Power Board Resistance Test Also check for leaky 8 If the input rectifier is faulty see the Input or faulty f
24. 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 Cuts parts in place circuit out put current is established and regulated Once the cur rent stabilizes the solenoid valve turns off removing the forward force on the piston The back pressure drives the piston and electrode away from the nozzle creating the plasma arc The air stream forces the arc out the ori fice of the nozzle This appears as a pilot arc which can then be transferred for cutting PRO CUT 80 LINCOLN E Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo O o Fle sis mim PEN o x giz Elit 513 olo cc a Return to Section TOC Return to Master TOC E 6 THEORY OF OPERATION FIGURE E 6 CONTROL AND DISPLAY BOARDS POWER BOARD INPUT LINE IGBT SWITCH CAPACITOR R E G DESS N N N E iG ili 7 s w 1 T
25. C H AIR PRESSURE SWITCH zo AomJo v SIGNAL 18 36VAC THERMOSTATS xurma OUTPUT CONTROL 115VAC AUXILIARY TRANSFORMER FAN MOTOR CONTROL AND DISPLAY BOARDS The control board receives status and analog feed back signals from the output board display board power board and various sensors The processor interprets these signals makes decisions and changes machine mode and output to satisfy the requirements as defined by the internal software The control board CURRENT TRANSFORMER CONTROL BOARD sor z WORK NOZZLE ELECTRODE MAIN TORCH TRANSFORMER OUTPUT BOARD CONNECTOR r m di U ozmrom 0 TRIGGER amp SAFETY AIR OLENOID REMOTE INTERFACE RECEPTACLE ELECTRODE amp TRANSFER CURRENT FEEDBACK PILOT ENABLE ELECTRODE SOLENOID ENABLE AIR SOLENOID ENABLE X mm o CSS Dr regulates the output of the machine by controlling the IGBT switching times through pulse width modulation circuitry See Pulse Width Modulationlin this section The display board receives commands from the con trol board and via indicator lights communicates PRO CUT 80 status and operating conditions to the user PRO CUT 80 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC ojo olo Fle sis xo im PEN o s DAP l olo cc a Return to Section TOC
26. CAPACITOR VOLTAGE TEST continued 6 Check for the appropriate voltages outlined 7 the test voltages do not meet the expect in Table 3 ed values as listed in Table F 3 the capaci tors or other components on the povver NOTE Voltages may vary with the input line board may be faulty Replace voltage Return to Section TOC Return to Master TOC NOTE If the capacitor voltages are NOT bal anced within 20 VDC the capacitors may need conditioning See the Maintenance section NOTE If the capacitor voltage is too high over 400 VDC or too low less than 220 VDC the control board will deactivate relay CR1 CR2 This will prevent output TABLE F 3 CAPACITOR VOLTAGES EXPECTED VOLTS DC AT CAPACITOR INPUT APPLIED TERMINALS 460VAC 325VDC 440VAC 311VDC 415VAC 293VDC 380VAC 269VDC Return to Section TOC Return to Master TOC 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 olo O o E 515 om PEN iz 818 olo cc a Return to Section TOC Return to Master TOC PRO CUT 80 LINCOLN 5 F 20 F 20 TROUBLESHOOTING amp REPAIR OUTPUT POWER BOARD RESISTANCE TEST AA WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and wi
27. R49 R91 R109 SE RD RBG ROE ACD REO ROO AO 75 5194092212 s 3 Sed VOLTAGE RE CAPACITORS MFD VOLTS RESISTORS OHMS R45 R48 R94 R50 R52 R101 R103 4 4 3 3 2 2 2 4 3 3 4 4 21 5 El 4 2 4 1 1 1 1 1 19 0 10 1 10 12 1 1 1 1 3 Return to Section TOC Return to Master TOC o o olo Fir E pu o o s 8 2 SS LE 515 ply c a ez Z I cr G 3440 18 Return to Section TOC Return to Master TOC NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the LINCOLN E ine LINCOLN Y maghing PRO CUT 80 G 8 PRO CUT 80 916011 AZER m 66 61 a doe YYYY Jet NEA oer NOILOANNOO Hiuya Y Y Y Y 3000 Y 9NIAYH STOHLNOO 40 HO S N3NOd NO2 1 IHL MOHS LON NO1103NN00 NOAWOO A a AVN WWHOVIC SIHL 3134000 V 40 ALITIEVSONVHOUSINI JHL 9NLO33V 100HLIM zer 1NIOd 30unos ATddNS da
28. Return to Master TOC E 7 E 7 THEORY OF OPERATION PROTECTION CIRCUITS Protection circuits are designed into the PRO CUT 80 machine to sense trouble and shut down the machine before the trouble damages internal machine compo nents Both overload and thermal protection circuits are included OVERLOAD PROTECTION The PRO CUT 80 is electrically protected from pro ducing higher than normal output currents If the out put current exceeds 85 90 amps an electronic pro tection circuit limits the current to within the capabili ties of the machine Another protection circuit monitors the voltage across the input filter capacitors If the filter capacitor voltage is too high too low or not balanced the protection cir cuit may prevent machine output THERMAL PROTECTION Two thermostats protect the machine from excessive operating temperatures One thermostat is located on the output choke and the other on the 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 fan is oper ating normally the power switch may be left on and the
29. 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 overtighten PRO CUT 80 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC olo O o Fle 515 om PEN o lx 818 olo cc a Return to Section TOC Return to Master TOC Return to Master TOC B 7 OPERATION A WARNING ELECTRIC SHOCK can kill e Turn off machine at the discon nect switch on the front of the machine before tightening cleaning or replacing consum ables 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 s 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
30. access hole The cord connector is designed for a cord diameter of 40 1 03 in 10 2 26 2mm if it becomes necessary to install a different input cord See Figure A 1 For three phase connection Replace the input power cord with a 10 AWG 4 lead cable Connect the leads of the cable to a fused power panel Make sure the green lead is connected to the panel and the panel is connected to a good earth ground Install in accordance with all local and national electric codes INPUT WIRE AND FUSE SIZE Fuse the input circuit with the super lag fuses or dela type circuit breakers recommended on thel Technical Specifications page Choose an input and grounding wire size according to local or national codes also see the Technical Specifications ace 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 PRO CUT 80 LINCOLN 5 A 6 A 6 INSTALLATION o 3 RECONNECT PROCEDURE FIGURE A 2 RECONNECTION DIAGRAM 6 S When received directly from the factory the machines 9 d are internally connected for 230 VAC Reconnection RECONNECT PROCEDURE ole will be necessary if a higher input voltage is used To 218 reconnect the Pro Cut to 460 VAC or to connect back A WARNING 2 2 to 230 VAC follow the directions as outlined below e Disconnect input power before tio Follow this procedure ONLY while the Pro C
31. all safety notes and precautions detailed throughout this manu al Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing the primary power board and fil ter capacitors for maintenance or replacement Return to Section TOC Return to Master TOC MATERIALS NEEDED 5 16 Nut driver 3 16 Allen type wrench 7 16 Wrench Phillips Head screw driver Torque wrench 3 8 Wrench Penetrox A 13 Lincoln E2529 Electrical Joint Compound This procedure takes approximately 40 minutes to perform olo olo E 515 45 0 PEN iz 818 olo cc a Return to Section TOC Return to Master TOC PRO CUT 80 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o amp o o O o 8 E 3 E o Return to Section TOC Return to Master TOC o o E E o iyi o x 5 o 51 51 TROUBLESHOOTING 8 REPAIR PRIMARY POWER BOARD AND FILTER CAPACITOR REMOVAL AND REPLACEMENT continued FIGURE 23 PRIMARY POWER BOARD REMOVAL REMOVAL PROCEDURE K Remove input povver from the PRO CUT 8
32. 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 PC board to the heat sink and capacitor assembly Make sure the capacitor terminals line up with the holes in the PC board and with the correct capacitor polari ties PRO CUT 80 10 11 12 13 14 LINCOLN 5 Assemble the eight socket head screws and pre torque them to 25 inch pounds Make certain the capacitors are lined up cor rectly so that when the capacitor bolts are assembled through the P C board there will NOT be any distortion to the P C board Finish tightening the eight screws to 40 48 inch pounds Assemble the tvvo Phillips Head screvvs pre viously removed Connect the J10 plug Connect leads 201 204 205 208 and 209 previously removed Torque to 75 IN LBS Connect leads 202A 207A 206 and 203A to the capacitor terminals Torque to 50 60 inch pounds Clear and reposition any leads that may be disturbed Replace wire ties Replace the case wraparound cover F 54 F 54 TROUBLESHOOTING amp REPAIR INPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT AA WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and
33. head cap screws shown in Figure F1 At the bottom of the PowerBoard 203 206 207 202 Use electrically insulated gloves and insu lated pliers Hold the body of the resistor and connect the resistor leads across the two capacitor terminals Hold the resistor in place for 10 seconds DO NOT TOUCH CAPACITOR TERMINALS WITH YOUR BARE HANDS Repeat the discharge procedure for the capacitor on the other two terminals Check the voltage across the terminals of all capacitors with a DC voltmeter Polarity of the capacitor terminals is marked on the PC board above the terminals Voltage should be zero If any voltage remains repeat this capacitor discharge procedure FIGURE F 1 LOCATION OF INPUT FILTER CAPACITOR TERMINALS POWER BOARD CAPACITOR TERMINALS gt o POVVER RESISTOR RIGHT SIDE OF MACHINE INSULATED GLOVES PRO CUT 80 LINCOLN 5 INSULATED PLIERS F 12 F 12 TROUBLESHOOTING 8 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 Return to Section TOC Return to Master TOC If for any reason you do not understand the te
34. 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 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
35. job and have taken all safety precautions t is important to follow these operating 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 e 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 e Push in and hold the Purge button to check or set the gas pressure Pull the pressure regulator cap out and turn it to set the pressure Adjust the gas regulator for 70 PSI for 25 foot 7 62m torches or 75 PSI for 50 foot 15 24m torches Release the Purge button PRO CUT 80 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo olo Fle 515 45 0 Hie o lx DP l olo cc a Return to Section TOC Return to Master TOC B 6 B 6 OPERATION
36. 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 gate signals WORK ELECTRODE 1 NOZZLE MAIN TRANSFORMER x c TORCH OUTPUT BOARD CONNECTOR r TRIGGER amp SAFETY AIR SOLENOID AN TORY TRIGGER amp SAFETY REMOTE INTERFACE RECEPTACLE ELECTRODE amp TRANSFER CURRENT FEEDBACK PILOT ENABLE ELECTRODE SOLENOID ENABLE AIR SOLENOID 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 th
37. screws and washers mounting the section input rectifier bridge to the center panel 3 Locate the input rectifier and the leads con assembly nected to it See Figure F 25 4 Identify and mark the leads connected to the rectifier terminals Return to Section TOC Return to Master TOC C ei 207 le 0959 A TOP VIEW olo O o E E CIS o iz 819 ciec 515 olo cc a FIGURE F 25 INPUT RECTIFIER LEAD LOCATIONS Return to Section TOC Return to Master TOC PRO CUT 80 LINCOLN 5 F 56 F 56 TROUBLESHOOTING 8 REPAIR INPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT continued 7 Carefully remove the input rectifier bridge 8 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 Return to Section TOC Return to Master TOC 9 Reconnect the 10 leads to the correct ter minals and torque the phillips head screvvs to 31 in lbs 10 Apply Dow Corning 738 Insulating Com pound to all six screw heads and termi nals The heavy input lead terminals should be against the rectifier terminals 11 Assemble case wrap around cover Return to Section TOC Return to Master TOC olo olo Fle 515 45 0 Hie o lx DAP olo cc a Return to Section TOC Return to Master TOC PRO CUT 80 LINCOLN 5 Return to Section T
38. to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manu al Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing the input rectifier bridge for main tenance or replacement MATERIALS NEEDED 3 16 Allen type wrench Phillips head screw driver Torque wrench Penetrox A13 Lincoln E2529 Electrical Joint Compound Dow Corning 738 Lincoln E2861 Electrical Insulating Compound This procedure takes approximately 16 minutes to perform Return to Section TOC Return to Master TOC olo olo E 515 45 0 PEN iz 818 cc a Return to Section TOC Return to Master TOC PRO CUT 80 LINCOLN 5 F 55 F 55 TROUBLESHOOTING 8 REPAIR ojo cate INPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT continued 5 8 9 5 VVith the phillips head screvv driver remove ole the lead terminals connected to the rectifier CAE 1 Remove input povver to the PRO CUT 80 terminals eli 513 2 Perform the Filter Capacitor 6 Using the 3 16 allen wrench remove the two 2 E Discharge Procedure detailed earlier in this cap head
39. topple over HIGH FREQUENCY INTERFERENCE PROTECTION The PRO CUT 80 employs a touch start mechanism for arc initiation This eliminates high frequency emis sions from the machine as compared with spark gap and solid state type high frequency generators Keep in mind though that these machines may be used in an environment where other high frequency generating machines are operating By taking the following steps you can minimize high frequency interference Make sure the power supply chassis is connected to a good earth ground The work terminal ground does NOT ground the machine frame Keep the work ground clamp isolated from other work clamps that have high frequency H the ground clamp cannot be isolated then keep the clamp as far as possible from other work clamp con nections When the machine is enclosed in a metal building several good earth driven electrical grounds around the periphery of the building are recommended Failure to observe these recommended installation pro cedures may cause improper function of the Pro Cut or possibly even damage the control system or power supply components PRO CUT 80 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC olo olo E 515 om PEN iz gin l olo cc a Return to Section TOC Return to Master TOC Return to Master TOC A 5 A 5 INSTALLATION INPUT CONNECTIONS AA WARNING ELECTRIC SHOCK can kil
40. ue EE B 5 2 Pilot EE B 5 2 Cutting Ree Le ET B 5 5 Safety Status ele ee B 6 o Usor E EU EE B 7 2 Preheat Temperature for Plasma Cutting B 7 z Procedure IRECOMMENGATIONS 2 aaa daya adana B 7 crc TE B 7 Thin Gauge Sheet sea ERR B 7 Thick Sections of Metal B 8 Suggestions for Extra Utility From the Pro Cut B 8 T Machine Interfaces azad Lee Leo dence Eege Ebene EUR Lena SUPR ao EE EA B 9 9 2 AVG Initteted NRI T W B 9 AO ele e E B 9 e E 2 o r 8 o B PRO CUT 80 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o E o o O o 8 E 3 E o m Return to Section TOC Return to Master TOC o o E E o iyi o x 5 o m OPERATION ep OPERATING INSTRUCTIONS Read and understand this entire section of operating instructions before operating the machine SAFETY INSTRUCTIONS A VVARNING 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 s h
41. with clean compressed air or nitrogen e Supply pressure must be between 80 psi and 150 psi e Flow rate should be approximately 6 0 cfm 170 I min NOTE Oil in the air supply to the PRO CUT 80 can cause severe problems Use only a clean air supply Connect the gas supply to the PRO CUT 80 s pneumatic nipple at the air filter See Figure A 3 e Compressed gas should be supplied to the fitting connection mounted on the filter at the rear of the machine If necessary this fitting can be removed allowing plumbing access through the 1 4 in 6 4mm NPT input port on the filter body AA WARNING CYLINDER could explode if damaged Keep cylinder upright and chained to a fixed support FIGURE A 3 COMPRESSED GAS CONNECTION 1 CASE BACK e Keep cylinder away from areas 2 PNEUMATIC NIPPLE where it could be damaged 3 AIR FILTER 4 FLEX TUBE TO REGULATOR INSIDE MACHINE Never lift machine with cylinder attached Never allow the cutting torch to touch the cylinder Keep oylinder away from live elec trical parts e Maximum inlet pressure 150 psi NOTE When using nitrogen gas from a cylinder the cylinder must have a pressure regulator Maximum psi from nitrogen gas cylinder to PRO CUT 80 regulator should never exceed 150 psi Install a hose between the nitrogen gas cylinder regulator and the PRO CUT 80 gas inlet PRO CUT 80 LINCOLN 5 A 8 A 8 INSTALLATION
42. you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing the control board for maintenance or replacement Return to Section TOC Return to Master TOC MATERIALS NEEDED 5 16 Nut driver Needle nose pliers This procedure takes approximately 15 minutes to perform olo olo E 515 45 0 Hie iz 818 cc a Return to Section TOC Return to Master TOC PRO CUT 80 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o amp o o O o 8 E 3 E o m o o E E o o x 5 o 41 41 TROUBLESHOOTING amp REPAIR CONTROL BOARD REMOVAL AND REPLACEMENT continued 4 Screws FIGURE F 16 CASE FRONT SCREW REMOVAL PROCEDURE 1 Remove input power to the PRO CUT 80 machine 2 Remove the wraparound cover and perform the Input Filter Discharge Procedure detailed earlier in this section 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 16 Carefully slide do not force the front away from the rest of the machine about one inch This wil
43. 0 machine Primary Povver Board With Input Filter Capacitors 4 Label the leads for reassembly 5 Remove Plug J10 and any necessary cable Remove the case wraparound and perform the Input Filter Capacitor Discharge 6 Procedure detailed earlier in this section Locate the primary power board and associ ated lead and plug connections See Figure F23 PRO CUT 80 LINCOLN 5 ties Using the 7 16 wrench remove leads 201 202 203 204 205 206 207 208 and 209 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o E o o O o 8 E 3 E o m Return to Section TOC Return to Master TOC o o E o iyi o x 5 o m 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 Heatsink Mounting Screws 4 Mounting Screws 2 Socket Head Screws 8 S 7 Using the Phillips Head screvv driver remove 9 Carefully remove the primary povver board the tvvo mounting screvvs from the top right of from the heat sink the primary povver board See Figure F 24 8 Using the 3 16 allen type vvrench remove A CAUTION the eight socket head screws and lock wash ers mounting the primary power board to the Be sure to follow the recommended static free heat sink meth
44. 4 CONTROL BOARD LEDs PRO CUT 80 CONTROL 63443 CONTROL BOARD LED DEFINITIONS LED1 Red This light indicates that 18 VAC is being supplied to the control board from the auxiliary transformer It also shows that the 18 VAC is being rectified and should be regulated to 15 VDC This 15 VDC supply is used to power the circuitry on the control board LED2 Red This light indicates that the 5 5 VDC is present This voltage is derived from the 15 VDC supply The 5 5 VDC supply is used to power the circuitry on the control board LED3 Red This light indicates that 18 VAC is being supplied to the control board from the auxiliary transformer It also shows that the 18 VAC is being rectified and should be regulated to 15 VDC This 15 VDC supply is used to power the circuitry on the control board FIGURE F 15 DISPLAY BOARD TEST POINTS PRO CUT 80 LINCOLN 5 L10721 DISPLAY BOARD REAR VIEW F 40 F 40 TROUBLESHOOTING amp REPAIR CONTROL BOARD REMOVAL AND REPLACEMENT A WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manu al Return to Section TOC Return to Master TOC If for any reason
45. 50K 150K o C8 CAE clc CAPACITOR EIS PRECHARGE ala UNDERVOLTAGE PROTECTION o 100 c m son own RELAY DRIVE A jk FROM CONTROL BD RECONNECT V 206 2 i 1K 1K 1 00K 1 00K DW DW 2 022 04 02 022 022 I k AEEEBER FIle RESISTORS PEAK DETECTOR cla TRANSFORMER 615 PRIMARY m 205 0245 al 013 T o 15V x 50 Hie 206 El T o ck 0 eof T o18 825VDC FILTER E E NOMINAL CAPACITOR x e o 5 3 203 _ o B208 e mz e o bi e TRANSFORMER e S LE PRIMARY FH I 208 24 3K OVERVOLTAGE Dia TO CONTROL BD PROTECTION AS ls e M SCONNECT ON MUSL PROTECTION e 203A m j HO f 202 ag DRNE 3 118 mer z 202A di RECONNECT S 54 ojo CONTROL GATE v o BOARD PWM DRIVE a six iik o 2 Tn C24 C12 2 8 Hi 22 022 ols L a B T V F CONVERTER ole o o r 1 s giz 2 E TERK CIE PRIMARY sw 15 204 2 mn LA ol 202 x cc A o Elay L9 232600 F LTER Ton NOMINAL CAPACITOR 150K 4 vo 000 5 OVERVOLTAGE 207 RESISTORS PROTECTION TRANSFORMER PRIMARY 201 Lo TESTE T iow 8 NEGATIVE 300 Volts 1kHz calibrated oC 207A NPUT RECTIFIER dF 9 5136 dV Se NOTE 202 203 206 8207 BOLT ON WITH FILTER CAPS FILE NAME 63518 1 NOTES GENERAL INFORMATION NA 5 OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE ELECTRICAL SYMBOLS PER ET HOUT AFFECTING THE INTER
46. 874 STAK TAW Pas 519400 221 221K 1 4W o o G 2 o o O o 8 c E 2 o 67 R70 RB7 R101 S19400 4752 47 5K 1 4 72 R195 S19400 150 1 5K 1 4W 73 107 519400 768 7 68K 1 4W 171 R82 R175 R177 S19400 130 1 3K 1 4W 19400 121 1 2 4W 19400 2213 221K 1 4W 19400 8252 82 5K 1 4W S19400 243 2 43K 1 4W 19400 681 6 81K 1 4W 19400 5621 5 62K 1 4W 19400 26R7 26 7 1 4W 19400 1212 12 1K 1 4V 16296 5 10K TRIMMER 19400 2670 267 1 4W 19400 2002 20K 1 4W 110812 39 50K 1 2W TRIMMER S19400 68 68 1K 1 4W R1 6 19400 4750 415 1 4W R188 19400 3922 39 2K 1 4V MM ONCE 2 INDUCTANCE HENR ES mr SSS RSR PESIS IANUE ICITIUT DINER INTEGRATED p2 0 7 T 1 51512818 10 33074A40P AMP QUAD HIGH PERF 5 TT a OAK 7 Ez Ez Ez Ez EE El 5 E 59 79 H83 R155 R167 114 120 R121 H122 R123 R13 132 140 R14 R152 173 174 2142 AA E SE selsi G 3443 183 Return to Section TOC Return to Master TOC NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC b
47. 9400 22T3 2211 1 S19400 8252 1 41 T S19400 2437 0311 109 19400 6811 519400 5621 T20 RT2T RT22 RT23 4 S19400 2BR7 26 1 4W EN 19400 1212 132 1 516206 5 HES 79400 2671 152 9200 2002 OK 1 4 10812 30 TW 2171 9400 6812 176 19400 4750 188 9400 3922 HESS 10812 08 RIMMER CAPACITORS MFD VOLTS EISEN Ei INDUCTANCE HENRIES S15128 C AR INTEGRATED CIRCUIT RESISTANCE OHMS D T ST5128 18 30724 Op AMP QUAD Ed 901 319284 ICE a a GUND EY THELNGOLNELECTRC CO mos seenen THE LINCOLN ELECTR C CO 5 INVERTER WELDERS Be GE eg suse CONTROL P C BD AS BLY CANADIAN THE LINCOLN ELECTRIC CO Pur TOLERAMCE RE beer apen no G 3560 1B3 z o o G 2 o o O o 8 c E 2 o E S Es 5 Es c l c l 4 z JAN E amp ij TS zT rol el E zT 5 D e CH E l amp xj EE x E ol T EH E z B a iz IMMER ES si ol 4 E f ES RS ES a co xj GE z el JE BEER el ES 1717 l z K nj m co E L LL pe Po pd pe pd pd pe pd p pe DIODE 21 1 420 po pd pd pd pd ii i 6000 1 pe pd pd pe pd pd pd pe pd pd
48. 9400 2671 19400 2430 1N5822 SCHOTTKY BARRIER DIODE 1N4936 TN5818 1N4742A 1N4733A HEADER HEADER HEADER HEADER HEADER RED LED 2N4401 HEXFET TRANS SS 2N4403 0 OHM 5W RESISTOR 2 67K 1 4W 243 1 4W Z1 D22 no LED2 LED3 1 Q2 03 2 R46 R187 SISISTSISETSTSTSTSTSTSTSTRTSTSTE g S R N Z Z S ols ES g l zj el xj z l SI d iz zj EN x sl zj z l Return to Section TOC Return to Master TOC R38 R39 4 9400 30R1 30 1 1 4V HERE 5 L REESEN 36777 Rood RS RT5 REO ROT R8 R103 S19100 1001 TK TAW 113 TT SOTO R17 R23 R26 R27 R61 R62 423 2 27 1 31 519400 1002 10K 1 4W R63 R68 R69 RB1 R84 R93 R94 R104 R106 R108 R134 R138 R139 R154 R156 R158 R160 R164 R165 R166 R178 R179 R180 R181 R182 1 1 mg TT 24073 1 10K 1 2W TRIMMER R19 R53 R55 R57 R85 R149 f S19400 5111 5 11K 1 4W 12 19400 10 0 101 4 H24 H35 R25 R47 R49 RBO RB9 R153 183 R28 R112 R115 R116 R117 R118 R133 29 R91 R102 9400 2210 221 1 4V S19400 1003 100K 1 4W S19400 332 3 32K 1 4W E S19400 8250 S19400 1004 S19400 619 6 19K 1 4W S19400 1502 15K 1 4W S19400 1 4 75K 825 1 4W 1M 1 4W 41 H60 R135 R184 R43 R44 R45 R130 R136 R137 R170 R171 R172 xl l ES E o o E o iyi o 2 E x 3 o 19400 2802 28 0K 1 2W 57 F4 R56 19400 1000 100 1 4 7 58 R76 R09 RT00 S19400
49. C or Less AC Input Voltage Fuse Super Lag Type 75 C at Circuit Breaker Copper Wire in Conduit AWG 60 Hertz Delay Type IEC Sizes 230VAC Single Phase 4 21 1mm 4 21 1mm 460VAC Single Phase 8 8 4mm 8 8 4mm Return to Section TOC Return to Master TOC 230VAC Three Phase 8 8 4mm 8 8 4mm 460VAC Three Phase 10 5 3mm 10 5 3mm PHYSICAL DIMENSIONS Height Width Depth Weight with Torch Cable 16 5 Inches 13 75 Inches 29 5 Inches 98 Ibs 44 5 kg 419 mm 349 mm 749 mm 25 ft cable 113 Ibs 51 4 kg 50 ft cable olo olo Fle 515 xo im PEN o lx 818 olo cc a Return to Section TOC Return to Master TOC PRO CUT 80 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC olo olo E 515 om PEN iz 818 olo cc a Return to Section TOC Return to Master TOC Return to Master TOC A 4 A 4 INSTALLATION Read this entire installation section before you start installation SAFETY PRECAUTIONS AA WARNING ELECTRIC SHOCK can kill e Turn the input power OFF at the disconnect switch or fuse box and discharge input capacitors before working inside the equip ment Do not touch electrically hot parts or electrodes with your skin or wet clothing Always connect the 80 grounding terminal located on the side of the Case Back Assembly to a good electrical earth ground Always wear dry
50. CAPACITOR VOLTAGE TEST continued Probe If the power board does not meet the acceptable readings outlined in Table 2 the board is faulty Replace See Power Board Removal and Replacement Procedure NOTE Complete power board and filter capacitor replacement is recom mended TABLE F 2 PRIMARY POWER BOARD RESISTANCE TEST POINTS TEST POINT TERMINALS ANALOG METER X10 RANGE 7 8 Acceptable Meter Readings Greater than 1000 ohms Less than 100 ohms Greater than 1000 ohms Less than 100 ohms Greater than 1000 ohms Less than 100 ohms Greater than 1000 ohms Less than 100 ohms Greater than 1000 ohms Less than 100 ohms Greater than 1000 ohms Less than 100 ohms Greater than 1000 ohms Less than 100 ohms Greater than 1000 ohms Less than 100 ohms If the power board passes the resistance test the IGBT portion of the board is good However other circuits on the power board may be faulty These circuits are NOT readi ly tested or serviceable Carefully reconnect leads 201 204 205 and 208 to their appropriate terminals Torque To 75 IN LBS Return to Section TOC Return to Master TOC PRO CUT 80 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o amp o o O o 8 E 3 E o Return to Section TOC Return to Master TOC o o E E o iyi o x 5 o 18 TR
51. CHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER A SUPPLY VOLTAGE NET POWER SUPPLY SOURCE POINT N7 COMMON CONNECTION 47771 FRAME CONNECTION EARTH GROUND CONNECTION elo olo E e E pu o o ix 8 2 El l cq a NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN E PRO CUT 80 cad ELECTRICAL DIAGRAMS oT PC BOARD ASSEMBLY POWER BOARD SEE SEEE PRO CUT 80 51 0288 RER m Se POVVER D3 D4 D5 D6 D7 D15 D16 D18 3 T12199 1 1N4004 D20 D21 D22 D23 D24 pr v 29 20 N4744A DZ1 DZ3 DZ5 DZ6 DZ8 DZ10 DZ12 DZ13 DZ14 Return to Section TOC Return to Master TOC DZ2 DZ4 DZ9 DZ11 HEADER DZ7 DZ15 DZ16 OPTOTSOLATOR OCIT 005 00H 02 03 04 05 FET SS IC PKG MOSFET SS R5 R6 R7 R8 R15 R16 R17 24376 2 40 10W R18 R33 R37 R54 R55 R56 E a 1 3 mu EN E S19400 1001 1K 1 4V 5 Y il x 19400 10R0 10 1 4W R61 R62 R63 R68 R69 R70 R71 CT EN 5 EN EN 5 3 BE 52 540 R23 R24 R25 R26 R34 R43 S19400 1503 150K 1 4W R51 R53 R98 R107 19400 1000 100 1 4W S19400 2213 221K 1 4W 114648 19 1K SW R28 R36 R38 R44 R47 R87 R88 R96 R118 R119 R29 R30 R31 R32 R73 R74 R75 R76 R77 R78 R80 R81 S19400 3162 31 6K 1 4W S19400 1002 10K 1 4W S19400 2432 24 3K 1 4W R39 R46
52. E LEADS TO SUPPLY CIRCUIT S D S R RED PLIED WITH INPUT CABLE W WHITE bss T GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES OUTPUT BASE CASE FRONT U BLUE O SUPPLY CIRCUIT PC BOARD N BROWN T GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES Y YELLOW J Ji 77 57 51 PROTECTIVE BONDING CIRCUIT MP Jg N B a TS OR CIRCUITRY OF A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING ae 0000000 Eeeee THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER D m N C PLACE A LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE T CONNECTOR CAVITY NUMBERING SEQUENCE CONNECTION SHOWN IS FOR 440 460V OPERATION VIEWED FROM COMPONENT SIDE OF BOARD 000 a oan angi ELECTRICAL SYMBOLS PER E1537 T J20 L10936 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine 3 PRO CUT 80 Return to Section TOC Return to Master TOC Ga ELECTRICAL DIAGRAMS G 3 SCHEMATIC CONTROL PC BOARD CONTROL_POT lt ic CURRENT PURGE C D 2 60 V_PWN Return to Section TOC Return to Master TOC
53. EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 d 2 Never coil the electrode lead around your body 2 d 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side 2 d 4 Connect the work cable to the workpiece as close as possible to the area being welded 2 d 5 Do not work next to welding power source PRO CUT 80 LINCOLN 5 Return to Master TOC Return to Master TOC o o E o 2 o iyi o c x E o Return to Master 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 3 b 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 gratin
54. EW Users wishing to utilize the Machine Interface can order a K867 Universal Adapter please adhere to the pin locations stated above or manufacture a 14 pin MS connector cable assembly PRO CUT 80 LINCOLN 5 B 9 B 10 NOTES LINCOLN o co FE i o tc n OOL J91Se N 01 UuunjeH OOL Jeep 01 UuunjeH OOL Jeep 01 uunjeH DOL Jeep 01 uunjeH B 10 OOL uonoes 0 uumeg OOL uonoes o uumeg OOL uonoes oj uumeg OOL uonoes o uumeg Return to Master TOC Return to Master TOC o o FE E E o o c x E o Return to Master Section C 1 Section C 1 TABLE OF CONTENTS ACCESSORIES E TEE Section C ODplons ACcessorles ax C 2 PRO CUT 80 LINCOLN P Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o E o o o o 8 E 3 E o Return to Section TOC Return to Master TOC o o E E o o x 5 o 2 ACCESSORIES GENERAL OPTIONS ACCESSORIES The following options accessories are available for your PRO CUT 80 from your local Lincoln Distributor K1681 1 Undercarriage A valet style undercarriage with pull out handle for machine only Provides torch and work cable storage 22147 043 Vortech nozzle with an 043 1 2 mm Orifice For 35 60 Amps 22147 053 Vortech nozzle with an 053 1 3 mm Orifice For 60 85 Amps
55. For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Return to Master TOC Read and understand the following safety highlights For additional safety information it is strongly recommended that you pur chase a of Safety in Welding amp Cutting ANSI Standard 249 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 Return to Master TOC o o E o E o iyi o c x E o Return to Master FOR ENGINE povvered equipment 1 a Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 SX 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors 1 c Do not add the fuel near an open flame weld ing arc or when the engine is running Stop the engine and allow it to cool before refuel ing to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting Do not spill fue
56. J21 and J22 Figure F 8 and Table F 6 from the wiring harness Cut any necessary cable ties See Figure F 8 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC PRO CUT 80 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo olo E 515 45 0 PEN iz 818 olo cc a Return to Section TOC Return to Master TOC F 29 F 29 TROUBLESHOOTING amp REPAIR T2 AUXILIARY TRANSFORMER TEST continued TABLE F 6 J21 AND J22 VOLTAGES H2 522 H4 7J22 H5 8J22 Brown 8J21 Brown 3J21 Red 2J21 Red 6J21 Blue 9J21 White 5 21 Blue 4J21 White 5 21 Yellow 1J21 Yellow 7J21 7 If the correct test voltages are present the 9 auxiliary transformer is good 8 If any of the voltages are missing or very low with the proper primary voltage applied the auxiliary transformer may be faulty 10 PRO CUT 80 LINCOLN 5 If the auxiliary transformer tests good but it does not function when connected to the PRO CUT 80 check the harness wiring to the auxiliary transformer See the Wiring Diagram When finished with the test replace plugs 21 and 22 and the case wraparound F 30 F 30 TROUBLESHOOTING 8 REPAIR TRIGGER CIRCUIT TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may re
57. Keep your head out of fumes e Use ventilation or exhaust to remove fumes from breathing zone _ CUTTING SPARKS can cause k fire or explosion Keep flammable material away Do not cut containers that have held combustibles ARC RAYS can burn A Wear eye ear and body protection PLASMA ARC can injure Keep your body away from nozzle and plasma arc Mas Operate the pilot arc with caution The pilot arc is capable of burning the oper ator others or even piercing safety clothing Observe additional Safety Guidelines detailed in the beginning of this manual PRO CUT 80 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC olo OJO Fle 515 xo im PEN o lx 18 olo ez Return to Section TOC Return to Master TOC Return to Master TOC B 3 B 3 OPERATION GENERAL DESCRIPTION The PRO CUT 80 is an inverter based constant cur rent continuous control plasma cutting povver source It provides superior and reliable starting characteris tics cutting visibility and arc stability When cutting expanded metal the PRO CUT 80 out performs the 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 go
58. LAY BOARD REMOVAL DISPLAY BOARD CASE FRONT 5 Locate the display P C board and the one 8 When replacing the display board carefully plug connected to it See Figure F 20 connect the plug into the board Make cer tain the plug is secure and the locking tab is 6 Gently remove the display P C board from in place the three mounting pins 9 Align the display board with the three mounting pins and slide the display board A CAUTION into place Be sure to follow the recommended static free 10 Carefully reposition the front assembly in methods for handling printed circuit boards place and install the four mounting screws Failure to do so can result in permanent damage previously removed to e eguipment 11 Inspect clear and secure all leads in prepa ration for the case wraparound reassembly 7 Depress the locking tab and remove the plug 12 Using the 5 16 nut driver install the case connector from the display board wraparound PRO CUT 80 LINCOLN 5 F 46 F 46 TROUBLESHOOTING 8 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 through
59. Lincoln Electric Co 22801 ST Clair Ave Cleveland Ohio 44117 1199 FAX 216 481 2309 SVM Number Page Number if necessary Your Company Your Name Please give detailed description below SD287 01 99 LINCOLN P
60. O CUT 80 LINCOLN 5 10 DEPRESS LOCKING TAB ON MOUNTING PIN MOUNTING PIN 8 Replace the five molex type plugs in their respective receptacles Be certain they are securely in place Carefully reposition the front assembly in place and install the four mounting screws previously removed Inspect clear and secure all leads before installing the case wrap around reassembly Using the 5 16 nut driver install the case wraparound F 43 F 43 TROUBLESHOOTING 8 REPAIR DISPLAY BOARD REMOVAL AND REPLACEMENT AA WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician 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 Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call or 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing the display board for maintenance or replacement Return to Section TOC Return to Master TOC MATERIALS NEEDED 5 16 Nut driver Screw driver This procedure take
61. OC Return to Master TOC Return to Section TOC Return to Master TOC o o E o o O o 8 E 3 E o Return to Section TOC Return to Master TOC o o E E o iyi o x 5 o 57 57 TROUBLESHOOTING amp REPAIR RETEST AFTER REPAIR Should a machine under test be rejected for any reason requiring the removal of any mechanical part that could affect the machine s electrical characteristics or if any electrical components are repaired or replaced the machine must be retested INPUT IDLE AMPS AND WATTS Output Current Range 35 85 Amps Maximum Open Circuit Voltage 335 Volts PRO CUT 80 LINCOLN E F 58 NOTES LINCOLN o co FE 9 o n OOL J91Se N 01 UuunjeH OOL Jeep 01 UuunjeH OOL Jeep 01 uunjeH QOL Jeep 01 uunjeH F 58 OOL uonoes 0 uumeg OOL uonoes o uumeg OOL uonoes o uumeg OOL uonoes o uumeg Return to Master TOC Return to Master TOC o o FE E E o o c x E o Return to Master G 1 ELECTRICAL DIAGRAMS WIRING DIAGRAM ELECTRICAL DIAGRAMS TABLE OF CONTENTS ELECTRICAL DIAGRAMS SECTION CONTROL PC BOARD SCHEMATIC 0000000 uvu R R ks li CONTROL PC BOARD ASSEMBLY CODE 10574 CONTROL PC BOARD ASSEMBLY CODE 10577 8 10578 POWER PC BOARD SCHEMATIC m i a 62 POWER PC BOARD ASSEMBLY
62. OUBLESHOOTING amp REPAIR PRIMARY POWER BOARD RESISTANCE TEST AND CAPACITOR VOLTAGE TEST continued CAPACITOR VOLTAGE TEST This test will help the technician to determine if the input filter capacitors are being charged equally to the correct voltage levels NOTE This test should only be conducted with the PRO CUT 80 connected for 400 VAC or above and with the appropriate input voltage applied TEST PROCEDURE 1 Remove main input power to the PRO CUT 80 2 Perform the Input Filter Capacitor Discharge Procedure detailed earlier in this section 3 Locate and familiarize yourself with the capacitor test locations on the primary power board Seel Figure F 3 PRO CUT 80 4 The following tests will be performed with the input power applied to the PRO CUT 80 BE CAREFUL ALWAYS REMOVE THE INPUT POWER AND PERFORM THE INPUT FILTER CAPACITOR DISCHARGE PROCEDURE BEFORE TOUCHING ANY MACHINE COMPONENT A WARNING ELECTRIC SHOCK can kill Have an electrician install and service this equipment e Turn the input power off at the fuse box before vvorking on equipment Do not touch electrically hot parts 5 Apply the correct input powert and turn ON the PRO CUT 80 T NOTE This test should only be conducted with the PRO CUT 80 reconnect switch and A jumper configured for 400 VAC and above LINCOLN 5 F 19 F 19 TROUBLESHOOTING amp REPAIR PRIMARY POWER BOARD RESISTANCE TEST AND
63. Return to Master TOC Return to Master TOC o E o o 2 o m Return to Master TOC Vievv Safety Info Vievv Safety Info o 2 gt z 2 iyi o 2 gt s SERVICE MANUAL Vievv Safety Info SVM146 A September 1999 PRO CUT 80 For use vvith machine code numbers 10573 10574 10577 10578 Safety Depends on You Lincoln arc vvelding 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 LINCOLN B e World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB S TE www lincolnelectric com SAFETY Ai WARNING d A CALIFORNIA PROPOSITION 65 WARNINGS A Diesel engine exhaust and some of its constituents are knovvn to the State of California to cause can cer birth defects and other reproductive harm 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
64. S OR CIRCUITI HAVING A COMMON CODE Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN E ELECTRIC PRO CUT 80 oA ELECTRICAL DIAGRAMS PC BOARD ASSEMBLY CONTROL BOARD CODE 10574 ONLY ITEM PART NO DESCRIPTION SED 230020 2 8 10 11 13 14 17 30 816668 5 022 50 C20 23 C24 031 034 035 C36 037 038 039 040 C41 247 49 51 053 55 63 C64 C65 C66 C68 C69 111577 52 513490 2 13490 93 S13490 126 S16668 11 0047 or 005 1400 50 21 39 018 50V 1 50 1 2 060 5 16 032 33 42 58 71 72 19 025 50 Return to Section Return to Master TOC o Zi S13490 25 4 7 35 13490 42 1 0 35 CITT STOTSTSTS S zs ol SS m ol n l po c l so ol s E e Ej 262 67 22 043 044 21 048 16668 9 516668 8 S13490 135 516668 4 S16668 13 S13490 108 S16668 3 S13490 19 S16668 10 112199 1 T5000 380pF7100 T 0 50V 270001750 T pr T00 15 100 100pF 100 1 8 20 4700pF 50 TN4004 l SR n El EES s s s 2122 Ea E EA m E S E o ZS S E zi z al 014 019 020 022 023 024 1 012 013 il SE G3443 1 D16 D17 D18 Q9 s 112705 37 112705 34 112705 23 112702 19 112702 52 S18248 4 S18248 10 S18248 16 S18248 6 S18248 8 113657 2 112704 68 112704 80 112704 69 113165 S1
65. THERMAL SIGNAL RQ HLMP 2450 gt gt SAFETY SIGNAL o o olo Fir E pu o o s 8 2 SS LE 515 ply c a HLMP 2350 HLMP 2655 HLMP 2400 J40 9QoooooooOoOoooooo EI m i o GENERAL INFORMAT ON LAST NO USED ELECTRICAL SYMBOLS PER E1537 R 20 02 CAPACITORS MFD 022 50V UNLESS OTHERWISE SPECIFIED 69 E RESISTORS Ohms 1 4 UNLESS OTHERWISE SPECIFIED LABELS NOTES DIODES 1 400V UNLESS OTHERWISE SPECIFIED A SUPPLY VOLTAGE NET N A SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY Q POWER SUPPLY SOURCE POINT NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE COMMON CONNECTION NUMBER 777 FRAME CONNECTION EARTH GROUND CONNECTION 10 31 97D 18920 Return to Section Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN E PRO CUT 80 SCH ELECTRICAL DIAGRAMS G 11 PC BOARD ASSEMBLY DISPLAY BOARD _ ELXEL 1 LIGHT BAR LED RED LIGHT BAR LED YELLOW LIGHT BAR LED YELLOW 06 Return to Section Return to Master TOC HT BAR LED GREEN FI AW Dim
66. UNCTION PROBLEMS PROBLEMS SYMPTOMS Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o amp o o O o 8 E 3 E o m Return to Section TOC Return to Master TOC o o FE E E o iyi o E x 5 o 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 80 Press the purge button and set the regulator to 70 psi 448 kPa Do not reset the air pres sure vvhile the air is off not flovv ing The pressure switch S5 or associated leads may be faulty See the VViring Diagram The control board may be faulty Replace The Safety LED is flashing Make sure there is a Lincoln PCT 80 torch connected prop erly to the PRO CUT 80 Make sure the torch consum ables are in place and in good condition Perform the Torch Continuity and Solenoid Test Check leads N E 364 and 369 between the torch recep tacle the output board and the Transformer See the Wiring Diagram The output board may be faulty Replace The Safety LED is lit and steady Press the reset button If the torch and consumables are properly installed the Safety LED should turn off 2 The reset button or associated wiring may be faulty See the Wiring Diagram Perform
67. a Return to Section TOC Return to Master TOC PRO CUT 80 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o amp 2 o o O o 8 E 3 E o Return to Section TOC Return to Master TOC o o E E o iyi o x 5 o 16 16 TROUBLESHOOTING amp REPAIR PRIMARY POWER BOARD RESISTANCE TEST AND CAPACITOR VOLTAGE TEST continued FIGURE F 3 PRIMARY POWER BOARD REMOVAL TEST PROCEDURE 1 Remove main input power to the PRO 4 CUT 80 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 3 PRO CUT 80 LINCOLN 5 Primary power board with input filter capacitors PRO CUT 80 POWER G3440 1 n2 e co 205 201 204 Sg 203 206 207 202 CAPACITOR C1 CAPACITOR C2 TERMINALS 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 F 2 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o E o o O o 8 E 3 o E o E o o x 5 o m F 17 6 F 17 TROUBLESHOOTING amp REPAIR PRIMARY POWER BOARD RESISTANCE TEST AND
68. age Circuit 10 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 11 When the test is complete remove input power and replace the case wraparound cover Return to Section TOC Return to Master TOC olo olo E 515 45 0 PEN o lx 818 olo cc a Return to Section TOC Return to Master TOC PRO CUT 80 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o E o o O o 8 E 3 E o m Return to Section TOC Return to Master TOC o o E E o iyi o x 5 o m F 38 TROUBLESHOOTING 8 REPAIR LOW VOLTAGE CIRCUIT TEST continued FIGURE F 13 OUTBOARD LOW VOLTAGE CIRCUIT TEST POINTS AND LEDs TEST POINT m re x20 PRO CUT 80 OUTPUT BOARD LED DEFINITIONS LED1 Red This light indicates that 24 VAC is being supplied to the output board from the aux iliary transformer It also shows that the 24 VAC is being rectified to approximately 28 VDC This DC voltage is used for the parts in place check for the torch circuit LED2 Red This light 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 incorpor
69. an the cutting current While one winding is conducting the other winding is at a lim ited voltage and aids in the arc transfer to and from the workpiece PRO CUT 80 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo olo Fle sis mio PEN o x giz ciec 513 olo cc a Return to Section TOC Return to Master TOC E 5 E 5 THEORY OF OPERATION FIGURE E 5 PLASMA OUTPUT BOARD AND TORCH POWER BOARD IGBT CAPACITOR IGBT IGBT INPUT LINE INPUT SWITCH RECTIFIER CAPACITOR m n ro4 e iomzzoomm AIR PRESSURE SWITCH zo Jom Jozxv OUTPUT CONTROL AUXILIARY TRANSFORMER OUTPUT BOARD AND TORCH The output board contains an Insulated Gate Bipolar Transistor IGBT which upon receiving a pilot signal from the control board either enables or disables the current in the pilot winding The cutting and pilot rectifier diodes are also incorporated in the output board There are two diodes for the pilot winding and four diodes for the cutting winding There are two P C board mounted current sensors One sensor regulates pilot and cutting current The other sen sor indicates to the control board when and how much current transfers to the workpiece The output board also includes the tigger circuitry the gas solenoid driver the electrode solenoid driver and the torch parts in place circuitry an
70. are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION The test will determine if the auxiliary transformer is functional when the correct primary volt age is applied to the primary winding Return to Section TOC Return to Master TOC MATERIALS NEEDED Volt ohmmeter Machine wiring diagram 5 16 Nut driver 230 VAC isolated power supply This procedure takes approximately 18 minutes to perform olo olo E 515 45 0 Hie iz 818 cc a Return to Section TOC Return to Master TOC PRO CUT 80 LINCOLN 5 F 28 F 28 TROUBLESHOOTING amp REPAIR olo o o T2 AUXILIARY TRANSFORMER TEST continued S 8 sim o 5 FIGURE 8 T2 AUXILIARY TRANSFORMER 9 S2 CIE 10 PIN SIS eic 6 1 AUXILIARY 7 TRANSFORMER 813 914 5 9 9 Plug J21 FE S 8 PIN E 4 2 2 2 EE AE e H4 5 PROCEDURE 1 Remove main input power to the PRO CUT 5 Carefully apply the 230 VAC isolated supply 80 machine to leads H1 located at the D1 input bridge 2 Perform the Input Filter Capacitor 75 and Ma Gesar the Discharge Procedure detailed earlier in this y section 6 Carefully check for the presence of the fol 3 Locate the auxiliary transformer See Fig F 8 Geet at ha appropriate leads at plugs J21 and J22 See 4 Locate and disconnect plugs
71. ated on the output board LED3 Green This light indicates that the air solenoid driver circuit is functioning When this LED is lit the air solenoid should be activated PRO CUT 80 G3439 PRO CUT 80 OUTPUT TEST POINT sch Le LED4 Green This light indicates that the trig ger circuit on the output board has been acti vated This LED should be lit when the torch or remote trigger is closed This trigger circuit on the output board then sends a signal to the control board LED5 Green This light indicates that the elec trode solenoid driver circuit is functioning When this light is lit the electrode solenoid should be activated The electrode solenoid should be energized during gas air pre flow time During pilot and cutting arc periods the LED should be off When the arc goes out the machine enters the post flow state Two seconds after the start of post flow the electrode solenoid is activated a few times The LED should blink to indicate this activity The electrode solenoid will then be energized for the duration of post flow The LED should be on LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o E o o O o 8 E 3 E o Return to Section TOC Return to Master TOC o o E E o iyi o x 5 o 39 TROUBLESHOOTING amp REPAIR LOW VOLTAGE CIRCUIT TEST continued FIGURE F 1
72. conducting for 1 microsecond The negative portion is the other IGBT group The dwell time off time is 48 microseconds both IGBT groups off Since only 2 microseconds of the 50 microsecond time period is devoted to conducting the output power is minimized MAXIMUM OUTPUT By holding the gate signals on for 22 microseconds each and allowing only 3 microseconds of dwell time off time during the 50 microsecond cycle the output is maximized The darkened area under the top curve can be compared to the area under the bottom curve The more dark area under the curve the more power is present 1 An IGBT group consists of two IGBT modules feeding one transformer primary winding FIGURE E 8 TYPICAL IGBT OUTPUTS 1 usec 48 Tusec 50 u sec MINIMUM OUTPUT 22usec 3usec 0 Se c 2 MAXIMUM OUTPUT PRO CUT 80 LINCOLN 5 E 10 NOTES LINCOLN o co FE i o tc n OOL J91Se N 01 UuunjeH OOL Jeep 01 UuunjeH OOL Jeep 01 uunjeH DOL Jeep 01 uunjeH E 10 OOL uonoes 0 uumeg OOL uonoes o uumeg OOL uonoes oj uumeg OOL uonoes o uumeg Section F 1 Section F 1 TABLE OF CONTENTS S TROUBLESHOOTING amp REPAIR SECTION 5 Troubleshooting amp Repair 222 2222 Section F 9 How to Use Troubleshooting Guide 2 PC Board Troubleshooting Procedu
73. 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 elf 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 problem is recreated by the substitution of the original board then the PC board was the problem Reinstall the replacement PC board and test the machine 6 Always indicate that this procedure was followed when warranty reports are to be submitted NOTE Follow
74. 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 2 Filter Capacitor Conditioning PRO CUT 80 400 460 VAC only A protection circuit is included to monitor the voltage across filter capacitors C1 and C2 In the event that the capacitor voltage is too high the protection circuit will prevent output The protection circuit may prevent output providing all these circumstances are met a Machine is connected for 400 460 or 460 575 VAC input b Machine did not have power applied for many months c Machine will not produce output when power is first switched on If these circumstances apply the proper action is to switch the machine on and let
75. d 261 JN3OVDON eum v qal l0349 ISIMHHLO SSN Mr Vi 9300 0 G310N 9138 1 03131034S SSIINN Wer suuo SHOLSISSH cer 0314103dS ISIMHSHLO SSIINN AOS ZZ0 SHOLOYdYO eer 18913 Mad ST08H8 21410913 zer NOLLVINHOJNI IVH3N39 YALLND V NSVTd dV 08 0350 ON 1971 OB J qi i E NOS o ITS e Dun xw 1 S SSYHO Alddh 83MOd m sissvHo lodo 4399141 Iv ini awos 3 GIONTIOS e Du mun ZOO E am 07 0 WANININ SLINOYIO N33NU38 NOLLYIOS T awos ou lt t er OU mee 41220N IEN wih de d rost rost A08 R I tdl 108 221 EN n TT AOBy SEN eer eau 1 e eer Y A0008 1001 300419373 180 0002 1700 S SSVHO DEEN ELECTRICAL DIAGRAMS XAY This diagram is for reference only It may not be accurate for all machines covered by this manual DN Lo NOTE 10114 A l wot ve osa ANH 1014
76. d RL ET E 7 Thermal Protection ji ee 7 Insulated Gate Bipolar Transistor IGBT Operation 3333883333 E 8 3 Pulse Width Modulation DW E 9 2 Minimum OUT Us as E 9 E Maximum ele LEE E 9 o FIGURE E 1 PRO CUT 80 BLOCK LOGIC DIAGRAM POWER BOARD MAIN TORCH TRANSFORMER OUTPUT BOARD C CONNECTOR E NM INPUT RECTIFIER O ozm oo DEER ACC TRIGGER amp SAFETY AIR SOLENOID Zem omzzoom o o E o iyi o c x E o AIR PRESSURE SWITCH REMOTE INTERFACE RECEPTACLE ELECTRODE amp TRANSFER CURRENT FEEDBACK 20 SIGNAL 18 36VAC THERMOSTATS Wes Sor m KS OUTPUT CONTROL AUXILIARY TRANSFORMER Return to Master TOC PRO CUT 80 LINCOLN 5 E 2 E 2 THEORY OF OPERATION FIGURE E 2 INPUT LINE VOLTAGE Return to Section TOC Return to Master TOC olo olo E E lim 1 6 o lx 818 olo cc a POWER BOARD INPUT LINE INPUT SWITCH RECTIFIER CAPACITOR CAPACITOR R E C N N E G 8 T H 115VAC AUXILIARY FAN MOTOR GENERAL DESCRIPTION The PRO CUT 80 is a constant current continuous control plasma cutting power source The inverter based power supply design is controlled by a micro proces
77. d remote interface circutry The output choke which is in series with both the pilot cir cuit and the cutting circuit provides current filtering to enhance arc stability The PCT 80 torch uses a patented touch start mechanism that provides superior starting performance over other touch start systems The torch head consists of 3 major parts torch body insulator and piston The insulator pro vides an 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 ELECTRODE SOLENOID ENABLE AIR SOLENOID ENABLE D SPLAY BOARD ELECTRODE MAIN TORCH TRANSFORMER OUTPUT BOARD CONNECTOR O ozmroo ux M TRIGGER amp SAFETY REMOTE INTERFACE RECEPTACLE ELECTRODE amp TRANSFER CURRENT FEEDBACK PILOT ENABLE sor x mrxzmmr I A copper nozzle vvith a patented internal svvirl is used to focus the arc A small precise hole in the end of the noz zle constricts the arc and increases the current density As the air enters the torch head it is directed between the electrode and nozzle for maximum electrode cooling A portion of the cooling air exits the chamber through vents in the side of the nozzle
78. e 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 output power board is faulty Replace See the 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 8 Carefully reconnect the leads and plugs previously removed Torque X2 X4 and B21 to 75 IN LBS Return to Section TOC Return to Master TOC PRO CUT 80 LINCOLN 5 F 23 F 23 TROUBLESHOOTING 8 REPAIR TORCH CONTINUITY AND SOLENOID TEST A WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manu al Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perfo
79. 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 9 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 10 Ne pas souder en pr sence de vapeurs de chlore provenant d op erations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas forte ment roxique ou autres produits irritants PR CAUTIONS DE S RET POUR LES MACHINES SOUDER TRANSFOR MATEUR ET REDRESSEUR 1 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 2 Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi 3 Avant de faires des travaux l interieur de poste la debrancher l interrupteur la boite de fusibles
80. e lead t vvill be nec essary to penetrate the silicon sealant 6 Check for the presence of 15 VDC on the control board a LED1 should be lit when 15 VDC is pre 3 Apply the correct input power to the machine sent See Figure F 13 See and carefully check for the follovving voltages Board LED Definitionsland Figure F 12 4 Check for the presence of approximately 32 Low Voltage Circuit Diagram VDC on the output board 7 Check for the presence of 15 VDC on the con a LED1 should be lit when 32 VDC is present trol board See Figure F 13 See Output Board LED a LED3 should be lit when 15 VDC is pre and Figure F 12 Low Voltage sent See Figure F 13 See Control Board Circuit Diagram LED Definitions and Figure F 12 Low b To verify the presence of 32 VDC check Voltage Circuit Diagram across capacitor C13 Make certain the voltmeter probes make good contact with the capacitor leads See Figure F 13 PRO CUT 80 LINCOLN 5 F 37 F 37 TROUBLESHOOTING amp REPAIR 8 Check for the presence of 5 VDC on the control board a LED2 should be lit when 5 VDC is pre sent See Figure F 14 See Control Board and 9 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 Return to Section TOC Return to Master TOC a 415 VDC should be present at leads 216 to 219 SeelFigure F 15 and Figure F 12 Low Volt
81. emperature for Plasma 5 7 nennen nennen nnn B 7 Procedure apo HR RAYA YARE NEEN ENEE SKIN NER ee B 7 EE DEIER EE ree ELI IAE II IEEE 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 oala e EE F 2 How to Use Troubleshooting G ldoe rrt uota d Return Ee eegreed F 2 MOUDIESHOOTING GUIDE e F 4 Test Procedures y F 10 Replacement Procedures AEN F 40 Electrical DIagrams asra amir enne ran EAR Section G Parts s NEEN Eed ech P 340 Series PRO CUT 80 LINCOLN 5 Section A 1 Section A 1 TABLE OF CONTENTS INSTALLATION SECTION o o m bi nstallation 8 Une A 2 E SUE A 4 DElECE Suitable e e EE A 4 le lee EE A 4 IMM OWNING ET A 4 TUD ME A 4 High Frequency Interference aaa airin A 4 o Input Electrical Connectloris uror Ene E RR YRRS A 5 o Ground Connection EE A 5 o 9 Input Power Cord Connector Installation nennen nnn A 5 Input Wire and Fuse Glze ee A 5 E Reconnect gre c r eeneg A 6 2 2 Gas INPUt
82. er develops the appropriate AC voltages to operate the cooling fan the control board and the plasma output board NOTE Unshaded areas of Block Logic Diagram are the subject of discussion PRO CUT 80 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o amp o o o E 5 o m Return to Section TOC Return to Master TOC o o E o o x 5 o 3 3 THEORY OF OPERATION POVVER BOARD LINE INPUT RECTIFIER somzzooma AIR PRESSURE SWITCH zo JAomJonv SIGNAL 18 36VAC THERMOSTATS OUTPUT CONTROL AUXILIARY TRANSFORMER PRECHARGE AND PROTECTION The input voltage is rectified by the input rectifier The resultant DC voltage is applied through the reconnect switch to the power board The power board contains precharging circuitry for the safe charging of the input filter capacitors Once the capacitors are precharged and balanced the control board activates the CR1 CR2 input relays This connects full input power to the filter capacitors When the filter capacitors are fully charged they act as power supplies for the IGBT switching circuit The Insulated Gate Bipolar Tran sistors supply the main transformer primary winding with DC current flow Seel GBT Operation discussion and diagram
83. eturn to Section TOC Return to Master TOC Return to Section TOC olo olo E 515 45 0 Hie o lx 818 olo cc a Return to Section TOC Return to Master TOC Return to Master TOC B 9 OPERATION MACHINE INTERFACE The PRO CUT 80 comes standard with a machine interface Interface signals provided include arc start arc initiated and arc voltage These signals are acces sible through the 14 pin MS connector on the case front ARC START The Arc Start circuit allows for triggering of the power source to commence cutting This circuit can be accessed through pins K and M of the 14 pin MS con nector The circuit has a 17 VDC nominal open circuit voltage and requires a dry contact closure to activate ARC INITIATED The Arc Initiated circuit provides information as to when a cutting arc has transferred to the work piece This circuit can be accessed through pins and J of the 14 pin MS connector The circuit provides a dry contact closure when the arc has transferred Input to this cir cuit should be limited to 0 3 A for either 120VAC or 30VDC ARC VOLTAGE The Arc Voltage circuit can be used for activating a torch height control This circuit can be accessed through pins D and G of the 14 pin MS connector The circuit provides full electrode to work arc voltage no voltage divider 335VDC maximum J 347 Arc Initiated Arc Start K 2A Ep M 4A 348 Arc Voltage 14 PIN BOX RECEPTACLE FRONT VI
84. 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 RIGHT SIDE OF MACHINE INSULATED GLOVES CAPACITOR TERMINALS POWER RESISTOR INSULATED PLIERS PRO CUT 80 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo O o E 515 45 0 PEN iz 818 olo cc a Return to Section TOC Return to Master TOC D 3 MAINTENANCE ROUTINE MAINTENANCE 1 Keep the cutting or gouging area and the area around the machine clean and free of combustible materials No debris should be allowed to collect which could obstruct air flow to the machine Every 6 months or so the machine should be cleaned with a low pressure airstream Keeping the machine clean will result in cooler operation and higher reliability Be sure to clean these areas FIGURE D 2 Power Output and Control printed circuit boards and heat sinks Power Switch Main Transformer Input Rectifier Examine the sheet metal case for dents or break age Repair
85. g is 70 75 psi The gas purge button must be pressed in to set pres sure GAS REGULATOR GUAGE Provides gas presssure reading as set by the gas regulator knob GAS PURGE BUTTON Used to check or set gas pressure Push in and hold to check pressure then continue to hold to set the pressure Shuts off gas when released RESET BUTTON Used to reset the machine following a safety circuit trip STATUS DISPLAY BOARD INDICATORS Four lights indicating Power Gas Low Thermal and Safety PILOT ARC CONSIDERATIONS The Pro Cut has a smooth continuous pilot arc The pilot arc is only a means of transferring the arc to the workpiece for cutting Repeated pilot arc starts in rapid succession is not recommended as these starts will generally reduce consumable life Occasionally the pilot arc may sputter or start inter mittently This is aggravated when the consumables are worn or the air pressure is too high Always keep in mind that the pilot arc is designed to transfer the arc to the workpiece and not for numerous starts without cutting When the pilot arc is started a slight impulse will be felt in the torch handle This occurrence is normal and is the mechanism which starts the plasma arc This impulse can also be used to help troubleshoot a no start condition CUTTING OPERATION When preparing to cut or gouge position the machine as close to the work as possible Make sure you have all materials needed to complete the
86. gs or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical 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 80 ARC RAYS can burn 4 a Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding Headshield a
87. gulators 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 Cylinders should be located Away from areas where they may be struck or subjected to physical damage A safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should 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 rec
88. hine 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 b Static Sensitive ohm resistive cord connected to a Devices grounded part of the equipment Handle only at frame Static Safe f you don t have a wrist strap touch an unpainted grounded part of the equipment frame Keep touching the frame to pre vent static build up Be sure not to touch any electrically live parts at the same time Workstations Reusable Container Do Not Destroy Tools which come in contact with the PC Board must be either
89. his 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 35 85 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 Input 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 In line coarse air filter e Preflow Postflow timing Preflow is eliminated if arc is re initiated in Postflow e Thermostatic Protection e Solid state overcurrent protection e Works with pure nitrogen for cutting nonferrous materials e Reconnectable for multiple input voltages Quick disconnect torch e Display indicators for machine status Unique electrode and Vortech nozzle design for optimum cooling and long life Swirl texture inside Vortech nozzle for better start ing reliability and higher quality cuts Unique drag cup design for durability and elimina tion of double arcing PRO CUT 80
90. ilter capacitors Rectifier Bridge Removal amp Replacement procedure See the Wiring Diagram and Return to Section TOC Return to Master TOC PRO CUT 80 LINCOLN F 15 F 15 TROUBLESHOOTING amp REPAIR PRIMARY POWER BOARD RESISTANCE TEST AND CAPACITOR VOLTAGE TEST AA WARNING Service and repair should be 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 Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION This test will determine if the primary power board has any shorted or leaky power diodes or Insulated Gate Bipolar Transistors IGBTs Also it will help to indicate any shorted input filter capacitors Return to Section TOC Return to Master TOC MATERIALS NEEDED Analog voltmeter ohmmeter multimeter Wiring Diagram 7 16 Wrench This procedure takes approximately 25 minutes to perform olo olo E 515 45 0 PEN iz 818 cc
91. ing this procedure and writing on the warranty report INSTALLED AND SWITCHED PC BOARDS TO VERIFY PROBLEM will help avoid denial of legitimate PC board warranty claims PRO CUT 80 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o amp o o O o 8 E 3 E o m Return to Section TOC Return to Master TOC o o E E o iyi o x 5 o 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 1 800 833 9353 WELD Machine is dead no output no fan no status indicator lights Make sure that the input power switch is in the ON position Check the input voltage at the machine Input voltage must match the rating plate and the reconnect panel Check for blown or missing fuses in the input lines and the 0 6 amp slow blow reconnect fuse Check the input power switch S1 for proper operation See the Wiring Diagram Check the leads associated with the power
92. ion TOC Return to Master TOC o o E o o O o 8 E 3 E o m Return to Section TOC Return to Master TOC o o E E o iyi o x 5 o m F 33 F 33 TROUBLESHOOTING 8 REPAIR TRIGGER CIRCUIT TEST continued FIGURE F 10 OUTPUT BOARD TRIGGER CIRCUIT TEST POINTS AND LEDS TEST POINT Te X20 PRO CUT 80 OUTPUT BOARD LED DEFINITIONS LED1 Red This light indicates that 24 VAC is being supplied to the output board from the aux iliary transformer It also shows that the 24 VAC is being rectified to approximately 32 VDC This DC voltage is used for the parts in place check for the torch circuit LED2 Red This light indicates that 12 VAC is being supplied to the output board from the aux iliary transformer It also shows that the 12 VAC is being rectified to approximately 17 VDC This DC voltage is used to power the trigger circuit and solenoid driver circuits incorporated on the output board LED3 Green This light indicates that the air solenoid driver circuit is functioning When this LED is lit the air solenoid should be activated PRO CUT 80 G3439 PRO CUT 80 OUTPUT TEST POINT Te LED4 Green This light indicates that the trig ger circuit on the output board has been activat ed This LED should be lit when the torch or remote trigger is closed This trigger circuit on the output board then sends a signal to the co
93. irs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 Return to Section TOC Return to Master TOC PRO CUT 80 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC olo olo E 515 45 0 Hie o lx 818 olo cc a Return to Section TOC Return to Master TOC Return to Master TOC F 10 TROUBLESHOOTING amp REPAIR INPUT FILTER CAPACITOR DISCHARGE PROCEDURE AA WARNING Service and repair should be performed by only Lincoln Electric factory trained person nel Unauthorized repairs performed on this equipment may result in danger to the tech nician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION This procedure will drain off any charge stored in the two large capacitors that are part of the power board assembly This procedure MUST be performed as a safety precau tion before conducting any test or repair procedure that requires you to touch internal components of the machine MATERIALS NEEDED
94. it idle for up to 30 min utes This is required to condition the filter capacitors after an extended storage time The protection circuit will automatically reset once the capacitor condition ing and resultant voltage levels are acceptable It may be necessary to turn the power switch off and back on again after this period PRO CUT 80 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo olo Fle 515 io AE Sls l olo cc a Return to Section TOC Return to Master TOC Maintenance FIGURE D 2 MAJOR COMPONENT LOCATIONS 1 Case Front 2 Base and Case Back 3 Center Panel Assembly 4 Output Board Heatsink 5 Power Board Assembly 6 Case Wraparound PRO CUT 80 LINCOLN 5 D 4 Section E 1 Section E 1 TABLE OF CONTENTS o e THEORY OF OPERATION SECTION o E Theory of Operation ssssssssssssssssssesssssee arana nenne enne n entente aka akar nnns nennen Section E 2 General Description tte rte aaa E 2 5 Input Line Voltage Contactor and Main E 2 c Precharge and Me e E 3 Malm lranstormers aaa epu ete E 4 Output Board and Torch aaa R y Rad RR NN ERR ec ERR E 5 Control and Display Boards ire tieniti rester YARAYA YARAR ee ERR E E iad E 6 M E 7 Overloa
95. k within 5 seconds of power up Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S FUNCTION PROBLEMS Make sure the PRO CUT 80 is reconnected correctly for the input voltage being applied Be sure to remove input power and wait at least one minute before changing the position of the input voltage range switch RECOMMENDED COURSE OF ACTION 1 Perform the Board Resistance Test and Capacitor Voltage Test 2 Perform the nput Rectifier 3 The control board may be faulty Replace The primary power board may be faulty Replace The machine powers up properly but there is no response when the gun trigger is pulled Only the power LED is lit Make sure the torch is connect ed properly to the PRO CUT 80 machine Make sure the air supply is con nected and operating properly Make sure the torch head con sumable parts are in place and in good condition Replace if necessary 1 Perform the Auxiliary Trans 2 Perform the Trigger Circuit 3 Perform the Gas Solenoid 4 Perform the Torch Continuity and Solenoid Test The control board may be faulty Replace The 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 nece
96. l 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 80 should be connected only by a qual ified electrician Installation should be made in accor dance with the U S National Electrical Code all local codes and the information detailed below GROUND CONNECTION The frame of the PRO CUT 80 must be properly grounded A ground terminal marked with the symbol s mounted on the case bottom directly behind the input power switch for this purpose The ground lead of the input power cord that is attached to the machine must be connected to this ground terminal See the National Electric Code for details on proper grounding methods Install in accordance with all local and national electrical codes INPUT POWER CORD CONNECTOR INSTALLATION The PRO CUT 80 is supplied with one 11 foot 3 35m 8 AWG 3 lead input power cord already connected to the machine A cord connector provides a strain relief for the input power cord as it passes through the left rear
97. l allow more working room to remove the control board FIGURE F 17 CONTROL BOARD MOLEX PLUG REMOVAL Return to Section TOC Return to Master TOC PRO CUT 80 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o E o o O o 8 E 3 E o m Return to Section TOC Return to Master TOC o o E E o iyi o x 5 o m F 42 F 42 TROUBLESHOOTING amp REPAIR CONTROL BOARD REMOVAL AND REPLACEMENT continued 5 Locate the control board and the five molex 6 type plugs connected to it See Figure F 17 Carefully remove the five molex type plugs by depressing the locking tabs and gently extracting the plugs from the PC board receptacles FIGURE F 18 CONTROL BOARD REMOVAL FROM MOUNTING PINS CONTROL BOARD 7 Using the needle nose pliers and screwdriv 9 er gently remove the control board from the eight mounting pins by depressing the tabs on the mounting pins and carefully removing the board from the pins See Figure F 18 Be sure to follow the recommended static free methods for handling printed circuit boards 12 Failure to do so can result in permanent damage to the equipment 8 When replacing the control board align the mounting holes with the eight mounting pins and gently slide the P C board onto the mounting pins until the board snaps onto the pins PR
98. l when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equip ment 1 e n 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 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot ELECTRIC AND MAGNETIC FIELDS N may be dangerous 2 a Electric current flowing through any conductor causes 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
99. ll 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 Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION This test will help the technician determine if the output power board is faulty Return to Section TOC Return to Master TOC MATERIALS NEEDED 5 16 Nut driver Analog Volt ohmmeter 7 16 Wrench This procedure takes approximately 18 minutes to perform olo olo E 515 45 0 Hie iz 818 cc a Return to Section TOC Return to Master TOC PRO CUT 80 LINCOLN 5 F 21 F 21 TROUBLESHOOTING amp REPAIR OUTPUT POWER BOARD RESISTANCE TEST continued FIGURE F 4 OUTPUT POWER BOARD LEAD LOCATIONS Return to Section TOC Return to Master TOC G3439 PRO CUT 80 OUTPUT TEST POINT D25 TEST POINT o o o o O o 8 3 o Return to Master D29 X20 Oo o EIS TEST PROCEDURE ES 2 1 Remove input power to the PRO CUT 80 4 Carefully remove leads X4 X2 B21 X20 X40 Q 2 machine and plugs J33 and J32 from the output wi board See Figure EA 18 2 Perform the
100. lnput Filter Capacitor SSES E Discharge Procedure detailed earlier in this 5 Using the analog ohmmeter perform the E t section resistance checks per Table EA m 3 Remove the torch assembly from the machine Return to Section TOC Return to Master TOC PRO CUT 80 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o E o o o 8 E 3 E o m o o E o o x 5 o TROUBLESHOOTING amp REPAIR OUTPUT POWER BOARD RESISTANCE TEST continued TABLE F 4 OUTPUT POWER BOARD RESISTANCE TEST POINTS Probe J33 Pin4 to Probe Terminal X2 Probe Terminal X2 to Probe J33 Pin4 Probe J33 Pin4 to Probe Terminal X4 Probe Terminal X4 to Probe J33 Pin4 Probe D29 Test Point to Probe Terminal X20 Probe Terminal X20 to Probe D29 Test Point Probe D29 Test Point to Probe Terminal X40 Probe Terminal X40 to Probe D29 Test Point Probe D29 Test Point to Probe J32 Pin14 Probe J32 Pin14 to Probe D29 Test Point CIRCUIT OR COMPONENT S BEING TESTED Diode A1 and associated trace Diode A1 and associated trace Diode A1 and associated trace Diode A1 and associated trace Diode A2 and associated trace Diode A2 and associated trace Diode A2 and associated trace Diode A2 and associated trace Transistor A2 and associated trac
101. n to Master TOC F 2 TROUBLESHOOTING 8 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 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 ha
102. nd filter lens should conform to ANSI Z87 standards 4 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal 23 FUMES AND GASES can be dangerous 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head 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 weldi
103. nes detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S CUTTING PROBLEMS Make sure the operating proce dure is correct for the process See the Operation 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 between the display board and the control board Check for loose or faulty con nections See the Wiring Diagram The control board may be faulty Replace The output board may be faulty Perform the Output Board Resistance Test The display board may be faulty Replace Ai CAUTION f for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 PRO CUT 80 LINCOLN 5 TROUBLESHOOTING 8 REPAIR Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual RECOMMENDED COURSE OF ACTION POSSIBLE AREAS OF MISADJUSTMENT S LED F
104. ng arc starts but sputters Make sure the operating proce 1 Perform the Torch Continuity badly dure is correct for the process and Solenoid Test See the section Of 5 The output board may be faulty this manual Replace Make sure the work clamp is connected tightly to the work piece The control board may be faulty Replace Return to Section TOC Return to Master TOC 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 olo olo Fle 515 45 0 PEN iz 818 olo cc a A CAUTION f for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 Return to Section TOC Return to Master TOC PRO CUT 80 LINCOLN E Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o amp o o O o 8 E 3 E o m Return to Section TOC Return to Master TOC o o FE E E o iyi o E x 5 o 7 7 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS The pilot arc is normal but the arc will not transfer to the workpiece Observe Safety Guideli
105. ng can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Also see item 1 b LINCOLN 5 Return to Master TOC Return to Master TOC o o E E o iyi o c x E o Return to Master 7 WELDING SPARKS can cause fire or explosion 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
106. nt in Step 6 carefully check for the presence of approxi Return to Section TOC Return to Master TOC o o amp o o O o 8 3 o m Return to Section TOC Return to Master TOC o o E E o iyi o E x 5 o 1 Remove input povver to the PRO CUT 80 2 machine Perform the Input Filter Capacitor Discharge Procedure detailed earlier in this section mately 15 VDC from plug J32 pin 3 lead 354 positive to plug J32 pin 14 lead 312 negative SeelFigure 10 Also see and related figures If the correct voltage is not present perform the Low Voltage Circuit 3 Locate the torch cable receptacle and leads 2 and 4 See Figure F 9 the Simplified Trigger Circuit Diagram These leads are best 8 If the correct voltage is present in the above 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 Definitions land related figures Apply the correct input power to the PRO CUT 80 Carefully check for approximately
107. ntrol board LED5 Green This light indicates that the elec trode solenoid driver circuit is functioning When this light is lit the electrode solenoid should be activated The electrode solenoid should be energized during gas air pre flow time During pilot and cutting arc periods the LED should be off When the arc goes out the machine enters the post flow state Two seconds after the start of post flow the electrode solenoid is activated a few times The LED should blink to indicate this activity The electrode solenoid will then be energized for the duration of post flow The LED should be on LINCOLN 5 F 34 F 34 TROUBLESHOOTING amp REPAIR TRIGGER CIRCUIT TEST continued FIGURE F 11 CONTROL BOARD LEDs Return to Section TOC Return to Master TOC PRO CUT 80 CONTROL 63443 Return to Section TOC Return to Master TOC 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 t
108. o Master TOC Return to Section TOC Return to Master TOC o o E o o O o 8 E 3 E o Return to Section TOC Return to Master TOC o o E E o o x 5 o MAINTENANCE D 2 Ai VVARNING 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 Turn off input power or disconnect input power lines 2 Remove the 5 16 in hex head screws from the side and top of the machine and remove wrap around machine cover 3 Be careful not to make contact with the capacitor terminals that are located on the top and bottom of the Power Board on the right side of the machine Obtain a high resistance and high wattage resistor 25 1000 ohms and 25 watts minimum This resis tor is not supplied with machine NEVER USE A SHORTING STRAP FOR THIS PROCEDURE Locate the two capacitor terminals large hex head cap screws at the bottom of the Power Board shown in Figure D 1 Use electrically insulated gloves and insulated pli ers Hold the body of the resistor and connect resistor leads across the two capacitor terminals Hold the resistor in place
109. oard repairs could result in damage to the LIM N ine LINCOLN Y PRO CUT 80 Gs ELECTRICAL DIAGRAMS G PC BOARD ASSEMBLY CONTROL BOARD CODE 10577 amp 10578 ONLY PART NO DESCRIPTION 2 CB 010 011 013 014 017 20 C23 024 031 084 035 36 C37 038 039 040 041 C47 C49 051 053 055 063 64 C65 066 68 069 3 T 513490121 0400 25 1215 2 513490 63 3490 71 D 50 1577 52 d 3490 72 3490 93 12 60 2 513490 126 15 16 32 33 42 058 8 S16664 071 072 19 25 50 3 S13490 25 1 026 628 630 654 657 8 51349042 1 35 C62 C67 22 043 044 3 516668 9 150pF 1 27 048 2 1660 8 1 515190 185 REENEN DEEN 80 mi ROL 63560 1 MM 1027 7 S16668 13 Jo SE 100 D cj oz 210 gg Return to Section Return to Master TOC R 2112 ola c Si S16668 3 S13490 19 D S16668 10 D9 16 lz KE ST SI mE 19 c c l cl ER s sil ol 2 m sel 4 s ES ES 014 019 020 022 023 024 D25 T DTT DT2 DT3 3 112705 37 19522 SCHOTTKY BARRIEN DIODE 15D16D17 D18 1 112705 3 12 05 23 1 022 2 12702 19 14742 1 112702 52 8248 4 8248 10 8248 16 8248 6 8248 8 D1 LED2 LED3 3 113657 2 Q2 Q3 3 112704 68 12704 80 12704 69 1 T13165 16 2 R46 R187 3 519400 2671 s s E z Is NI D z El Fi male 9 2363 E ISERP o el ele cl o olo SE E iin
110. ods for handling printed circuit boards Failure to do so can result in permanent damage to the equipment PRO CUT 80 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o E o o O o 8 E 3 E o Return to Section TOC Return to Master TOC o o E E o o x 5 o 53 53 TROUBLESHOOTING amp REPAIR PRIMARY POWER BOARD AND FILTER CAPACITOR REMOVAL AND REPLACEMENT continued CAPACITOR REMOVAL 1 Using the 3 8 wrench remove the four screws holding the heat sink to the center panel assembly Take note of the insulator placement for reassembly The four screws have insulating washers on both sides of the panel assembly These must be properly replaced upon reassembly Carefully push the heat sink in towards the center of the machine This is necessary to gain clearance for capacitor s removal Carefully slide the capacitor s from the heat sink assembly Observe polarity markings and terminal position CAPACITOR REPLACEMENT AND P C BOARD REPLACEMENT 1 Carefully slide the new capacitor s into the heat sink assembly Reassemble the heat sink assembly to the center panel using the four screws and insu lated washers previously removed Note insulation placement Position the capacitors to the PC Board for assembly Note the polarity of the capacitors Apply a thin
111. ommendations LINCOLN 5 Return to Master TOC Return to Master TOC o o E E o iyi o c x E o Return to Master SAFETY PRECAUTIONS DE S RETE Pour votre propre protection lire et observer toutes les instructions et les precautions de s rete specifiques qui parraissent dans ce manuel aussi bien que les precautions de s rete generales suiv antes S rete Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits a l lectrode et a la piece sont sous tension quand la machine a souder est en marche Eviter tou jours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains b Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un planch 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 a souder en bon et s r tat defonctionnement d jamais plonger le porte electrode dans l eau pour le refroidir 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
112. 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 e Follow safety precautions as printed throughout this manual and on the machine THIN GAUGE SHEET METAL Torch Standoff Machine Output Setting DRAG thru 1 16 Standoff Output Setting Min thru Mid Range Output set below 45 Amps 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 PRO CUT 80 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC olo olo E 515 45 0 PEN iz 818 olo cc a Return to Section TOC Return to Master TOC Return to Master TOC B 8 OPERATION THICK SECTIONS OF METAL Torch Standoff Machine Output Setting 1 8 thru 3 16 Standoff Output Setting Mid thru Max Range Output set above 45 Amps The best quality and consumable life vvill 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 vvork Use of the 522151 Drag Cup will maintain the
113. ould be replaced immediately It is recommended that consumables be replaced in complete sets Example Electrode and Nozzle This will maximize the performance of the PRO CUT 80 system LIMITATIONS Do not exceed output current and duty cycle rating of machine Do not use the PRO CUT 80 for pipe thaw ing PRO CUT 80 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC olo O o E 515 om PEN iz 818 olo cc a Return to Section TOC Return to Master TOC Return to Master TOC B 5 B 5 OPERATION CONTROLS AND SETTINGS FIGURE B 2 CASE FRONT CONTROLS Gas Purge Gas Button Regulator Gauge Reset Status Button Indicators Output Gas Control Regulator Knob Knob LINCOLN D Consumable PRO CUT 80 Storage behind door Input Te Povver sir Switch Connector Cable Interface Connector OUTPUT CURRENT CONTROL KNOB Adjusts the amount of cutting current applied Affects cutting speed dross formation cut width heat zone and trav el speed TORCH CONNECTOR Quick connect type coupling for the PCT 80 cutting torch WORK CABLE Provides clamp and cable connection to workpiece ON OFF POWER SWITCH Turns machine on or off GAS REGULATOR KNOB Adjusts compressed gas pressure delivered to the torch Length of torch hose is an adjustment factor Optimum settin
114. out this manu al Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing the output power board for main tenance or replacement Return to Section TOC Return to Master TOC 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 olo olo E 515 45 0 Hie iz 818 cc a Return to Section TOC Return to Master TOC PRO CUT 80 LINCOLN 5 F 47 F 47 TROUBLESHOOTING 8 REPAIR OUTPUT POWER BOARD REMOVAL amp REPLACEMENT continued FIGURE F 21 OUTPUT POWER BOARD REMOVAL Return to Section TOC Return to Master TOC OUTPUT POWER BOARD Return to Section TOC Return to Master TOC PROCEDURE 1 Remove input power to the PRO CUT 80 23 Locate the output power PC board and machine associated lead and plug connections See Figures F 21 and 2 Remove the case wraparound and perform the Input Capacitor Filter Discharge Procedure detailed earlier in this section ojo O o Fle 515
115. 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 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 1 Occasionally an oxide layer may form over the tip of the electrode creating an insulating barrier between the electrode and nozzle This will result in the tripping of the Pro Cut s safety circuit When this happens turn the power off remove the noz zle and electrode and use the electrode to rub against the inside bottom surface of the nozzle This will help remove any oxide buildup Replace the nozzle turn on the power and continue cutting If the Parts in Place circuit safet
116. ransformer 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 olo olo Fle 515 45 0 PEN iz DAP olo cc a Return to Section TOC Return to Master TOC PRO CUT 80 LINCOLN 5 F 35 F 35 TROUBLESHOOTING amp REPAIR LOW VOLTAGE CIRCUIT TEST Ai 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 Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION These voltage checks will help the technician determine if the correct voltages are being applied and processed by the various P C boards Some of the voltage verification test points are not easily accessible The presence of these voltages can also be confirmed by LEDs on the various P C boards Return to Section TOC Return to Master TOC MATERIALS NEEDED 5 16 Nut driver Volt ohmme
117. res and Replacement AA F 3 E Troubleshooting Guide F 4 Test Procedures Input Filter Capacitor Discharge Procecdure F 10 Input Rectifier est eren x Ra Yaa aa cede cannes 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 F 23 Air Gas Solenoid Test F 25 O T2 Auxiliary Transformer 5 27 E lge eeler Oe F 30 5 Low Voltage Circuit Test iecit d ARA A Aya rt us a o dan Eege F 35 9 Replacement Procedures z Control Board Removal and 1 F 40 8 Display Board Removal and Replacement F 43 Output Power Board Removal and Replacement sse F 46 t Primary Power Board and Filter Capacitor Removal and Replacement F 50 c Input Rectifier Bridge Removal and F 54 EE F 57 o o m iyi 8 2 o o m g E E o m PRO CUT 80 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC olo olo E 515 45 0 PEN iz 818 olo cc a Return to Section TOC Return to Master TOC Retur
118. reset should occur within a 15 minute period If the fan is not turning or the air intake louvers are obstructed the input power must be removed and the fan problem or air obstruction must be corrected PRO CUT 80 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC olo O o E 515 om PEN iz 818 olo cc a Return to Section TOC Return to Master TOC Return to Master TOC 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 posi
119. rm the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION This procedure will help the technician determine if the torch cable consumables and elec trode solenoid are functioning properly Return to Section TOC Return to Master TOC MATERIALS NEEDED Volt ohmmeter 12 VDC 1 Amp Power Supply This procedure takes approximately 15 minutes to perform olo olo E 515 om Hie iz 818 cc a Return to Section TOC Return to Master TOC PRO CUT 80 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o E o o O o 8 E 3 E o m Return to Section TOC Return to Master TOC o o E o iyi o x 5 o m F 24 F 24 TROUBLESHOOTING 8 REPAIR TORCH CONTINUITY AND SOLENOID TEST continued FIGURE F 5 TORCH CONNECTOR MACHINE END TEST PROCEDURE 3 Using the ohmmeter check the torch resis tances per Table F 5 1 Remove input power to the PRO CUT 80 machine NOTE Take the 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 ma
120. s sary Make sure the air pressure is set at 70 psi 448 kPa Make sure there are no kinks or restrictions for air flow in the torch cable 1 Perform the Torch Continuity and Solenoid Test 2 Perform the Low Voltage Circuit Test The output board may be faulty Perform the Output Board Resistance Test The control board may be faulty Replace A CAUTION f for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 PRO CUT 80 LINCOLN E 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 Return to Section TOC Return to Master TOC 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 cutti
121. s approximately 15 minutes to perform olo olo E 515 45 0 Hie o lx 818 olo cc a Return to Section TOC Return to Master TOC PRO CUT 80 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o E o o O o 8 E 3 E o m Return to Section TOC Return to Master TOC o o E E o iyi o x 5 o m F 44 F 44 TROUBLESHOOTING amp REPAIR DISPLAY BOARD REMOVAL amp REPLACEMENT continued FIGURE F 19 CASE FRONT SCREW REMOVAL 4 Screws PROCEDURE 1 Remove the input power to the PRO CUT 80 4 machine 2 Remove the wraparound cover and perform the Input Filter Capacitor Discharge detailed earlier in this section 3 Using the 5 16 nut driver remove the four screws holding the front assembly to the top and base of the machine See Figure F 19 PRO CUT 80 LINCOLN 5 Carefully slide do not force the front away from the rest of the machine about one inch This will allow more working room to remove the display board Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o E o o O o 8 E 3 E o m Return to Section TOC Return to Master TOC o o E o iyi o x 5 o m F 45 F 45 TROUBLESHOOTING amp REPAIR DISPLAY BOARD REMOVAL amp REPLACEMENT continued FIGURE F 20 DISP
122. s in this section CONTROL BOARD ELECTRODE SOLENOID ENABLE AIR SOLENOID ENABLE i DISPLAY BOARD lt o gt mp Sor x x es DR MAIN TORCH TRANSFORMER ONNECTOR ay he eal dy TRIGGER amp SAFETY AIR SOLENOID REMOTE INTERFACE RECEPTACLE ELECTRODE amp TRANSFER CURRENT FEEDBACK PILOT ENABLE The power board also monitors the filter capacitors for voltage balance and under or overvoltage If either should occur the appropriate signal is sent to the con trol board to deactivate the CR1 CR2 input relay The machine output will also be disabled NOTE Unshaded areas of Block Logic Diagram are the subject of discussion PRO CUT 80 LINCOLN E Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo O o Fle 515 mim PEN o x giz ciec 513 olo cc a Return to Section TOC Return to Master TOC EA THEORY OF OPERATION FIGURE EA MAIN TRANSFORMER POWER BOARD INPUT LINE INPUT SWITCH RECTIFIER R ER bl fo N N E d BE 8 if Tm H AIR PRESSURE SWITCH 20 4 4 0 OUTPUT CONTROL 115VAC AUXILIARY TRANSFORMER FAN MOTOR MAIN TRANSFORMER Each IGBT pair acts as a switch assembly Each assembly feeds a separate oppositely wound primary winding of the main transformer The reverse direction of current flow through the main transformer
123. sor control board The control system has a safety mechanism to insure that the nozzle and elec trode are in place before cutting or gouging The PRO CUT 80 initiates the plasma arc with a simple yet reli able touch start mechanism This system eliminates many of the problems associated with hi frequency type start systems When powered up the machine performes some rudimentary self diognostics l TRANSFORMER FF m NOZZLE ELECTRODE MAIN TORCH TRANSFORMER OUTPUT BOARD CONNECTOR xc ccc TRIGGER amp SAFETY AIR OLENOID 1 e Ojo AIR R TRIGGER amp SAFETY O PRESSURE o o T REMOTE KE It A sulu E CRAT O INTERFACE Cla T T DR VE RECEPTACLE o SIGNAI ELECTRODE amp TRANSFER Q L S CURRENT FEEDBACK mim E SIGNAL Old PILOT ENABLE d CONTROL BOARD ELECTRODE SOLENOID ENABLE o 18 36VAC AIR SOLENOID ENABLE g keng H W S CIE DEE Al amp H mi MH E Fe 5 Y 9o vl x e wW f olo OUTPUT l ojo CONTROL i DISPLAY BOARD 2 INPUT LINE VOLTAGE SWITCH AND MAIN TRANSFORMER The single phase or three phase input power is con nected to the machine via an input line cord to a switch located on the front panel A reconnect panel and voltage range switch allow the user to configure the machine for either a low or high input voltage and also connect the auxiliary trans former for the appropriate input voltage The auxiliary transform
124. st procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION This test will help determine if the input rectifier has shorted or open diodes Return to Section TOC Return to Master TOC MATERIALS NEEDED Analog voltmeter ohmmeter multimeter Phillips head screw driver Wiring diagram This procedure takes approximately 15 minutes to perform olo O o E 515 om PEN iz 818 olo cc a Return to Section TOC Return to Master TOC PRO CUT 80 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o 2 5 o o 8 E 2 E o ra Return to Section TOC Return to Master TOC o o E E o o x 5 o 13 13 TROUBLESHOOTING 8 REPAIR INPUT RECTIFIER TEST continued TEST PROCEDURE 4 With the phillips head screw driver remove D leads 207 207A and 209 from the rectifi 1 Remove main input power to the machine er 2 Perform the Input Filter Capacitor b 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 Carefully remove the silicone sealant from leads
125. sult 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 Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION The procedure will help the technician determine if there is a problem or fault in the inter nal trigger circuit Return to Section TOC Return to Master TOC MATERIALS NEEDED Ohmmeter voltmeter multimeter 5 16 Nut driver Simplified Trigger Circuit Diagram This procedure takes approximately 19 minutes to perform olo olo E 515 45 0 Hie o lx 818 cc a Return to Section TOC Return to Master TOC PRO CUT 80 LINCOLN 5 F 31 F 31 TROUBLESHOOTING amp REPAIR TRIGGER CIRCUIT TEST continued FIGURE F 9 SIMPLIFIED TRIGGER CIRCUIT DIAGRAM SIMPLIFIED TRIGGER CIRCUIT Return to Section TOC Return to Master TOC OUTPUT BOARD CONTROL BOARD 415VDC TORCH RECEPTACLE TRIGGER SWITCH IN TORCH HANDLE 8 2 S S R 15 0 20 AUX COM COM PROCEDURE 7 f the correct voltage is prese
126. switch S1 and the auxiliary transformer T2 for loose or faulty connections See the Wiring Diagram Perform the Auxiliary Trans former Test Machine is dead not output no status indicator lights fans run All status indicators remain lit immediately after power up Check the input voltage at the machine Input voltage must match the rating plate and the reconnect panel The microprocessor has experi enced a memory fault Contact your Local Lincoln Authorized Field Service Facility 1 Perform the Transformer Test 2 Perform the Low Voltage Circuit Test 3 Perform the Input Rectifier The control board may be faulty Replace The display board may be faulty Replace The control board may be faulty Replace A CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 PRO CUT 80 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o amp o o O o 8 E 3 E o m Return to Section TOC Return to Master TOC o o E E o iyi o E x 5 o 5 5 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS All the status lights begin to blin
127. t 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 See the Wiring Diagram If the leads are good the solenoid coil may be faulty 6 Carefully apply the 12 VDC supply to the solenoid leads at plug J31 positive to J31 pin 6 lead 366 and negative to J31 pin 5 lead 361 With proper air pressure applied the sole noid should activate and air should flow If the solenoid activates but air does not flow check for a restriction in the air line Install plug J31 back into the output power board FIGURE F 7 PLUG J31 LOCATION TEST POINT D29 G3439 PRO CUT 80 OUTPUT TEST POINT PRO CUT 80 LINCOLN 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 Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or
128. ter multimeter This procedure takes approximately 20 minutes to perform olo olo E 515 45 0 Hie iz 818 cc a Return to Section TOC Return to Master TOC PRO CUT 80 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC olo olo E 515 45 0 Hie o lx 818 olo cc a Return to Section TOC Return to Master TOC Return to Master TOC F 36 F 36 TROUBLESHOOTING amp REPAIR LOW VOLTAGE CIRCUIT TEST continued FIGURE F 12 LOW VOLTAGE CIRCUIT DIAGRAM T2 AUXILIARY TRANSFORMER CG TOH1 C TERMINAL BROWN VAC prown 8561 6 0 PLASMA OUTPUT RED DER eil va BOARD Se 24VAC RED l 6 54 EE TO marc AT bx BLUE D x 18VAC rel d 6 2 5 m l CONTROL BOARD 415VDC S M 18VAC BLUE l g 57 9 2 219 Y J21 PROCEDURE 1 Remove input power to the PRO CUT 80 5 Check for the presence of 17 VDC on the out machine put board 2 Using the 5 16 nutdriver remove the case a LED2 should be lit when 17 VDC is present wraparound cover Seel Figure F 13 SeelOutput Board LED Definitions and Figure F 12 Low Voltage A WARNING Circuit Diagram b To verify the presence of 17 VDC check ELECTRIC SHOCK can kill from plug J31 Pin 6 to diode D25 anode See Figure F13 F 13 Make certain the volt 0 meter probes make good contact vvith pin 6 and the diode anod
129. ter TOC 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 follovv 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 povver board to the heat sink and pre torque the four socket head screvvs to 25 inch pounds 3 Finish tightening the four screvvs to 40 48 inch pounds 4 Replace the four phillips head screvvs previ ously removed 5 Replace leads X20 and X40 6 Replace plugs J30 J31 J32 J33 and J34 7 Replace leads X4 and X2 then torque to 75 IN LBS 8 Replace lead B21 and torque it to 75 IN LBS 9 Clear and secure all leads and replace the wraparound cover PRO CUT 80 LINCOLN 5 F 49 F 50 F 50 TROUBLESHOOTING amp REPAIR PRIMARY POWER BOARD AND FILTER CAPACITOR REMOVAL AND REPLACEMENT AA WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe
130. 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 element and replace with new element Assemble parts in reverse order as described above Inspect the cable periodically for any slits or punc ture marks in the cable jacket Replace if neces sary Check to make sure that nothing is crushing the cable and blocking the flow of air through the air tube inside Also check for kinks in the cable periodically and relieve any so as not to restrict the flow of air to the torch PERIODIC MAINTENANCE A WARNING ELECTRIC SHOCK can kill Turn off machine at the disconnect svvitch on the front of the machine before tightening cleaning or replacing
131. tive 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 lt BUFFER LAYER p lt INJECTING LAYER DRAIN A PASSIVE POSITIVE VOLTAGE S APPLIED GATE SOURCE Q ZA ZA BODY REGION DRAIN DRIFT REGION lt BUFFER LAYER lt INJECTING LAYER DRAIN B ACTIVE PRO CUT 80 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o E o o O o 8 E 3 E o Return to Section TOC Return to Master TOC o o E o iyi o x 5 o THEORY OF OPERATION PULSE VVIDTH 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
132. uging This is extremely important due to the high voltages involved The PRO CUT 80 comes standard with an air regula tor coarse air filter and pressure gauge There are six different torch and cable systems to choose from hand held torch with 25 or 50 cable machine and robotic torch both with 25 and 50 cable Consumables are included so that cutting can begin right out of the box Consumables can also be ordered as individual packages The PRO CUT 80 initiates the plasma arc with a sim ple yet reliable touch start mechanism This system eliminates many of the failure problems associated with hi frequency start systems The PRO CUT 80 is capable of cutting with nitrogen or air The PRO CUT 80 is controlled by a microprocessor based control board The machine performs rudimen tary self troubleshooting when powered up which aids in field servicing RECOMMENDED PROCESSES AND EQUIPMENT The PRO CUT 80 is capable of all cutting and gouging applications within its output capacity of 35 to 85 amps These applications include thin gage sheet metal and expanded metal OPERATIONAL FEATURES AND CONTROLS The PRO CUT 80 comes with an ON OFF POWER SWITCH OUTPUT CURRENT CONTROL PURGE BUTTON STATUS INDICATORS and a SAFETY RESET BUTTON SeelFigure B 2land related discus sion DESIGN FEATURES AND ADVANTAGES The microprocessor controlled PRO CUT 80 design makes plasma cutting and gouging tasks uncompli cated T
133. ut is dis inspecting or servicing machine mim connected from the input povver Do not operate with wraparound removed ELECTRIC Do not touch electrically live parts A CAUTI N SHOCK Only qualified persons should install CAN KILL use or service this equipment Failure to follow these instructions can cause immedi ate failure of components in the welder 1 BE SURE POWER SWITCH IS OFF 2 CONNECT LEAD A TO DESIRED INPUT VOLTAGE RANGE 440 460V 1 Open the access door on the side of the machine ee 380 415V Connection instructions are also included on the inside of the door SCHEER 200 208V 2 For 230 Position the large svvitch to 200 230 See 3 POSITION SWITCH TO DESIRED INPUT VOLTAGE RANGE Return to Section TOC Return to Master TOC Figure A 2 For 460 Position the large switch to 380 460 See D Figure A 2 VOLTAGE z 380 460V 3 Move the A lead to the appropriate terminal 2 9 Bg 1 VOLTAGE 200 230V olo olo E 515 45 0 PEN iz 818 olo cc a Return to Section TOC Return to Master TOC PRO CUT 80 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o o o O o 8 E 3 E o m Return to Section TOC Return to Master TOC o o E E o iyi o x 5 o m A 7 INSTALLATION GAS INPUT CONNECTIONS Supply the PRO CUT 80
134. ve 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 proceed Call 1 800 833 9353 PRO CUT 80 LINCOLN 5 F 2 Return to Section TOC Return to Master TOC Return to Section TOC olo O o Fle 515 45 0 PEN iz 818 olo cc a Return to Section TOC Return to Master TOC Return to Master TOC F 3 TROUBLESHOOTING amp REPAIR PC BOARD TROUBLESHOOTING PROCEDURES AA WARNING ELECTRIC SHOCK can kill Have an electrician install and service this equipment Turn the mac
135. ximum None leads Pin 7 to Torch One pilot arc lead to 1 0 ohm maximum Torch consumables Nozzle nozzle in place Pin 8 to Torch One pilot arc lead to 1 0 ohm maximum Torch consumables Nozzle nozzle in place Pin 1 to Pin 9 Torch trigger circuit 100K ohms minimum Torch trigger NOT pulled not activated Pin 1 to Pin 9 Torch trigger circuit 1 0 ohm maximum Torch trigger pulled activated Pin 2 to Pin 3 Electrode Solenoid 45 to 55 ohms None Pin 7 to Torch Pilot and Electrode 1 0 ohm maximum Torch consumables Electrode at machine circuit in place end of torch Pin 8 to Torch Pilot and Electrode 1 0 ohm maximum Torch consumables Electrode at machine circuit in place end of torch 4 If any of the resistance checks are not cor 5 Carefully apply the 12 VDC supply to the rect the torch assembly may be faulty electrode solenoid positive to Pin 2 and Repair or replace negative to Pin 3 The electrode solenoid should activate Listen for the solenoid action in the torch handle If the solenoid does not activate it may be faulty Replace PRO CUT 80 LINCOLN 5 F 25 F 25 TROUBLESHOOTING amp REPAIR AIR GAS SOLENOID TEST AA WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec
136. y 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 45 Amps b Make sure the air supply to the Pro Cut is clean and free of oil Use several extra in line filters if necessary c Use the lowest output setting possible to make a good quality cut at the desired cut speed d Minimize dross buildup on the nozzle tip by starting the cut from the edge 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 PRO CUT 80 LINCOLN 5 R

Lincoln Electric PRO-CUT SVM146-A User's Manual

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