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Lincoln Electric SVM149

1. 99 13 EN 4 5 5 2 2 2 82 2 a a SPECIFICHE DI COLLAUDO 003 SCHEMA ELETTRICO 98056rev4 N A NON MONTARE SEGUENTI COMPONENTI R11 R12 IC3 C7 TOLLERANZE 0 2 SALVO GIA DOVE ESPRESSAMENTE INDICATO VIETATA LA DIVULGAZIONE NON AUTORIZZATA DEL PRESENTE DOCUMENTO contains proprietary information owned by LINCOLN ELECTRIC ITALIA S R L and is not to be reproduced disclosed or used without the express permission of LINCOLN ELECTRIC ITALIA S R L LINCOLN ELECTRIC ITALIA s r l F AVORAZION CELLE LIGURE SV ITALIA 5 25 090699A SCALA __________ DATA 02 12 98 NUMERO DI DISEGNO DATA DISEGN C D APPR ________ WO505600 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 r
2. i iii INS HAM Section Technical Specifications 2 3 Select Proper Location sisi A 3 3 MEME UE Mc IEEE A 3 High Frequency Interference Protection A 3 Input Electrical Connections sise A 3 Gas Input 4 Output 4 0 5 5 rincer Section 5 B 2 Descriptio 2 Preh ating uices d E AE a IY 2 User RESPONSIDINMSS 3 Operational Features and 3 Design Features and B 3 M 4 Consumable B 4 stu EE 5 Controls and Settings eiie
3. PILOT PATH PIP PATH V Trigger when open Must double hit when first turned on CN common for on inverter bd lt to input safety feature or after thermo reset trigger direct to control bd ky REF bd K card B 12 Vs OK over 0 volts i load signal nozzle ckt 15Vrms 12V Ov overload choke thermo or input bd 12 gt MS 20A gt 7 see pip ckt inset detail Air Solenoid see pip ckt inset detail 3bars Thermo indicates that the 12 on inverter bd is up not the 8 also pip input overload reset by turning off PC25 comes on if no gas psi Output Control control bd mounted all LED s come on initally then just the POWER led is lit THERMO led stays lit for approx 3 sec also at turn on comes at turn on for3 sec Purge Switch n o Schematic 99016 SPA25 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual deer bd ain Inverter Board 8vdc min 10 5 vdc max power supplies from inverter bd for pot only not so in preflow torches of 15 or 25 ft are Solenoid 2 Torch solenoid supply from inverter
4. 12VDC Display LED s Purge Solenoid Switch 1 Control Board Output Control OUTPUT SECTION AND TORCH The output section contains a relay which upon receiving a pilot signal from the control board will enable the operation of a pilot arc or a cutting arc The printed circuit board mounted current sensor regulates the pilot and cutting current The output choke which is in series with both the pilot circuit and the cutting circuit provides current filtering to enhance arc stabil ity The PCT 20 torch uses a patented touch start mecha nism 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 provides an electrical barrier between the piston and torch body The piston provides a path for electrical current to the electrode The piston also dri ves 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 Figure 10 8 G Section or more detail A copper nozzle with a patented internal swirl is used to focus the arc A small precise hole in the end of the nozzle 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 elec trode cooling A portion o
5. Codice Descrizione Rif topografico 1020056 5 5 6 OHM 0 25W 5 R9 1020150 5 15 OHM 0 25W 5 R7 1021470 5 470 OHM 0 25W 5 R5 R6 R8 1024470 5 470K OHM 0 25W 5 R4 1124330 RES 330K OHM 0 5W 5 R2 R3 1221470 RES 47 OHM 1W 5 R13 1521180 5 180 OHM SW 5 R10 1701040 5 10 OHM 10 R1 W3042470 D CER 4700pF 100V X7R 10 04 W3043105 ND CER O tuF 50V 5 08 10 5 W3083470 D BOX 470nF 630V 10 C3 D D Return to Section TOC Return to Master TOC LATO COMPONENTI lt W3410220 COND ELRAD 220uF 100V 20 6 W3416472 ELRAD 220uF 25V 20 2 W3435150 COND ELRAD 1500uF 35V 20 W4004148 01000 144148 D4 D5 411000 1 100 1 5A 1KV 01 02 03 W4207907 01000 ZENER 5 1V 071 44300184 TRANS NPN 10 92 BC 184 02 04 44304408 TRANSISTOR NPN 04488 1 03 W450062A OPTOISOLATORE 17 3 W4607805 INTEGRATO 7805 5V WO5338A1_ SCHEDA CSI 20U logica W5998057 TRASFORMATORE AUSILIARIO W6000009 FASTON MASCHIO PER C S W6110108 ETTORE MODU2 8X AMP W7005600 CIRC STAMP SIPC25 W7130220 RELE 2 SCAMBI 2A 6Vdc W7162430 RELE 3 SCAMBI 16A 110V W7165610 RELE1 30 12Vdc x C S W7301000 FUSIBILE RITARDATO W7900630 PER FUSIBILE W8093008 VITE ACCIAIO ZINC M3x8 W8100003 RONDELLA ACCIAIO W8110003 RONDELLA DENTA
6. NR Ee E 3 4 Outp t Section i Een ene 5 Control BOard E 6 Protection CICUS ced 7 Overload Protector Ea eH ES Han ER E 7 5 Thermal Protect On E 7 5 Accidental Op ration Protection era Ee e a ed ARES 7 9 Safety Parts In Place Protection 7 2 Insulated Gate Bipolar Transistor IGBT E 8 FIGURE 1 PRO CUT 25 BLOCK LOGIC DIAGRAM gt WORK CLAMP 8 IRGABC30W 010 Lout 2s 1 pi I WRK 2 26 5 240uH gt 1 8 11 2 8 300uH gt pril T 3 25 5 ab 0117 NZL 2 zg C12 5 2 1 2 2 di o 5 02a O R24 5 Q2a b c 6 8k 5W IRG4BC30W Es 5 SHUNT 2 8 C13 Y o L SH SH s gt T a 2 5 3 6 4 3 2
7. PART 4 IL LIVELLO FASE 2 PAG 2 2 un e LATO COMPONENTI TOLLERANZE 0 2 SALVO GIA DOVE ESPRESSAMENTE INDICATO VIETATA LA DIVULGAZIONE NON AUTORIZZATA DEL PRESENTE DOCUMENTO ARRIVARE A contains proprietary information owned by LINCOLN ELECTRIC ITALIA S R L and is not to be reproduced disclosed or used without the express permission of LINCOLN ELECTRIC ITALIA S R L TOCCARE PIN DEL LINCOLN ELECTRIC ITALIA s r l COMPONENTI CONNETTORE CELLE LIGURE SV ITALIA INVERTER 25 100699 SCALA 17 02 1999 juo DATA DISEGN 0 APPR WO504400 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 ine LINCOLN machine PRO CUT 25 os ELECTRICAL DIAGRAMS G 8 PC BOARD ASSEMBLY INPUT BOARD 2
8. 2 2 212 5 5 aja Return to Section TOC Return to Master TOC Return to Master TOC _ Follow safety precautions as printed throughout this operating manual and on the machine f 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 careful Blow the dross away from the torch the operator and any flammable objects The nozzle may be dragged on the metal sur face touching it lightly to the surface NOTE The use of a drag cup with the PRO CUT is not recommended The increased standoff distance reduces the overall performance of the PRO CUT Torch Standoff DRAG thru 1 16 Standoff Where possible start the cut from the edge of the work piece Keep moving A steady speed is necessary Do not pause 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 replacing consumables help remove any oxide buildup Replace the noz zle turn on the power and continue cutting If the safety circuit continues to trip after cleaning the consumables then replace them with a new set Do not continue t
9. B 5 Controls and Settlrigs ee Eua HERE ER Ha RR e a ERR reet B 5 5 Pilot cabelas B 6 Procedure 7 2 CICER B 7 c Suggestions for Extra Utility From the Pro Cut B 7 o O a tc o 2 E E PRO CUT 25 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC E olg 2 212 5 5 Return to Section TOC Return to Master TOC Return to Master TOC Read and understand this entire section before operat ing the machine SAFETY PRECAUTIONS WARNING lt ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground Always wear dry insulating gloves FUMES AND GASES can be dangerous Keep your head out of fumes SE Use ventilation or exhaust to remove fumes from breathing zone 2 WELDING CUTTING and 4 GOUGING SPARKS can cause fire or explosion Keep flammable material away Do not weld cut or gouge on containers that have held combustibles ARC RAYS 7 can burn AZ Wear eye ear and b
10. Return to Master TOC Return to Master TOC Q 2 5 Return to Master TOC Section C 1 Section C 1 TABLE OF CONTENTS ACCESSORIES hen A a eee Section C EEE EEEE C 2 PRO CUT 25 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 Return to Section Return to Master TOC o 2 5 ACCESSORIES ia ALWAYS USE GENUINE LINCOLN ELECTRIC ELECTRODES AND VORTECH NOZZLES Only Genuine Lincoln Electric consumables yield the best cutting performance for the PRO CUT 25 The patented VORTECH nozzle provides an extra kick of swirl as the arc exits the nozzle which improves cutting performance No other nozzle has this capability or can match its performance GENERAL OPTIONS ACCESSORIES The following options accessories are available for your PRO CUT 25 from your local Lincoln Distributor 22147 028 VORTECH nozzle with an 028 0 7 mm Orifice 22149 Electrode replacement electrodes for cut ting 22150 Shield Cup This shields the nozzle and pro vides more visibility to the workpiece Note the s
11. gt 8 2 Return to Section Return to Master TOC E THEORY OF OPERATION FIGURE E 3 PRECHARGE AND PROTECTION z WORK CLAMP IRG4BC30W 010 cas 5 5 EE 8 8 L1 Exi A RL3 RL 2 46 5 gt T2 300uH Ri a PRI SEC RL Chop Rijs as 10 10W lt 5 gt 011 f 4 5 gt 02 RL2 p H a 2 2 E Ju Aq T vi RL2 5 Q2a b c 2 115VAC 8 IRG4BC30W 1 gt 5 3 El ey 613 230V RL1 1 E 5 CN2 7 Li Main Inverter Board Solenoid 2 Input Voltage Board 15161218141 114 137 19242123 8 1 1 2 3 4 ES 1 5 lt e n lo E Es el lt 2 lt lt 36 5 5 2 2 2 5 5 z o ES D le o m gt 2 3 lt 8 6179 3 2 18147 154 115 16101213 2 1 12VDC 1 Display LED s Air Purge Solenoid Switch Output Control Control Board PRECHARGE AND PROTECTION The input voltage is rectified by the input rectifier on inverter board a
12. 3 Select Proper LOCATON ies 3 SLACKING 3 O A 3 High Frequency Interference Protection siens A 3 Input Electrical Connections is A 3 Gas Input 4 Output CONNECTIONS js e eue de nau ERES em E EUER ead eus A 5 Molte me A 5 Return to Master TOC o 2 5 Return to Master TOC PRO CUT 25 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC olg 2 8 mlt 5 5 Return to Section TOC Return to Master TOC Return to Master TOC iin INSTALLATION TECHNICAL SPECIFICATIONS PRO CUT 25 1756 1 INPUT SINGLE PHASE 60 HERTZ ONLY Standard Voltage 10 Input Current at Rated Output 115 230 1 50 60Hz 15 20 26 7A 60 37 7A 35 15 A 100 19 60 20 115 100 230 20 35 115 25 60 230 25 OUTPUT Current Open Circuit Pilot Current Range Voltage 12 25 Amps 400 VDC 12 Amps REQUIRED GAS FLOW RATE REQUIRED GAS INLET PRESSURE 55 PSI 240 SCFH 65 to 150 PSI 3 8 Bar 6800 LHR 4 5 Bar TO 10 3 Bar RECOMMEND INPUT WIRE AND FUSE SIZES For al
13. E 6 E 6 THEORY OF OPERATION FIGURE E 6 CONTROL BOARD AE WORK CLAMP S IRG4BC30W DAC 009 BSI wrk s c26 2 5 4 8 Li 1 5 a pen k 2 SEC 12VDC TRANSFER 28 5 0112 NZL 2 z A m R24 2a b c 6 8k 5W IRGABC30W SHUNT EL 8 C13 Y SH SH CN3 PT T 3 4 20 Main Inverter Board Solenoid 2 Voltage Board um LAA SUIASE N 4 5 5 5 Ep MS 20 201 MS A8 OND 235 0701 0 MS 8345 105 105 399141 114110 1 0 A 104 M9 104 104 019 235 al al al E 23222 12VDC Ar Display LED s Purge Solenoid Switch 1 Control Board Output Control CONTROL BOARD The control board receives status and analog feedback signals from the inverter board input board and various sensors The control circuitry interprets these signals makes decisions and changes the machines mode and output to satisfy the requirements as defined by the circuitry The control board sends a signal to the inverter board to control the output current but the actual regulation circuits are on the inverter board The display board directly connected to the control board communicat
14. 7 TROUBLESHOOTING 4 REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS Will only cut thin gauge material or cutting cutting is 1 2 of what it should be Cuts for 3 seconds then quits POSSIBLE AREAS OF MISADJUSTMENT S FUNCTION PROBLEMS The ground lead or clamp is dis connected Unit is not transferring to cut mode TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION Replace or repair clamp or cable Clamp directly to the piece to be cut Look for the transfer signal from the inverter board to the control Board per the enhanced dia gram Possible replacement of the inverter board per the signal of the enhanced diagram Possible replacement of the Control Board per the signal of the enhanced diagram Use the correct extension cord See the instruction manual When nothing is described for your problem or you have performed your test with no solution Unplug and re plug in all the printed circuit board harness connectors 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 1 888 935 3877 PRO CUT 25 LINCOLN 5 eS TROUBLESHOOTING amp REPAIR F 8 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginni
15. DETAILS E E G 9 PRO CUT 25 LINCOLN 5 G 2 ELECTRICAL DIAGRAMS me WIRING DIAGRAM PRO CUT 25 WORK CLAMP Q1a b c SE IRG4BC30W 9 8 2 C26 o 98 u t Y Y Y 2 300uH gt 5 gt 7 vi _ gt 5 2a b c 2 115VAC A IRG4BC30W L1 v2 Ojo E 5 5 min 518 CN2 als 15VAC 9 22 9 L15VAC 10 3 5 4 28VDC 6 5 al Main Inverter Board 7 2 Voltage Board 1516121814 1 114 137 19242123 8 17 1 2 3 4 111 lt 111 EI E O _ PP EN EPL 1 S o lt 20 AE 5 2 9 gt olm 2 2 55 lt 8 6 179 3 1 2 1814 7 15 4 11 5 16101213 23 22 24 2 8 sis m a 12VDC n Display LED s Solenoid Switch 1 Output Control Control Board sit NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine LINCOLN amp PRO CUT 25 Return to Section TOC Return to Master TOC Return to Section TOC Re
16. ojo 5 5 4 3 2 1 Q 9 Hybrid 2 12V_IN 8V Hybrid 1 A LM7808 A 11115 5 14 27 45 I g E 01 2 R10 80438 R32 14 10k 5 gt 8V 680 RIS R17 RI R3 R4 R6 c iac 743 vto 16k 470k 6 8 2k 10k 22k 220k D Re 12V_IN 12V_IN 186 AE LED a lu LOW ERROR 500 25V R13 5 ZX R8 10k 2 2k 21 1k 5 2130 12V_IN i E 4 PIP DETECT A 5 OUVLUAD SAFETY LM358D LOW ERROR 8 5V LM358D LDW ERRDIRD oe 26 i 5 R9 R33 R16 2 T 470 10k CF40 10k 1 cre 4 cs 04 1004 3360 47u 100u 100u 4 6 4 50 gt gt 59 25 1 25 50 n 5 LOW VOLTAGE DETECT SAFETY DETECT no s 9 Hybrid 2 8V Hybrid 1 8v 8 TRANSFER DUTPUT o TRANSFER SW R59 10 33 37 R64 R42 R45 R47 10k 10k 470k 10k 8 390k R62 R63 R66 R44 D504B U4E R49 XZ 25144 390k 1k u 10 i n jo 100k 40106 100k D514B R58 R46 5 U2B R60 1 1 220k 7 Q4 0509 R57 LM3580 35098 Z ws 10 12 MAX PILOT TIME 5 DETECT OCV TIME Vout 300k LM3580 LDW ERROR 1 LM324D LOW 0CV t LM324D LDW ERRDRD Tal R56 R61 Re5 R43 R48
17. 3 2 Blue Leads White amp Black Pairs NZL 2 E th air tube o pilot 8 A cls 1 2 2 2 Red Leads FRE D 5 Torch Trigger 2 TEST PROCEDURE 7 Using the ohmmeter check the torch 515 resistances per Table F1 5 5 1 Remove input power to the PRO CUT 25 ITAA machine 8 If any of the resistance checks are not cor rect the torch assembly may be faulty 2 Remove carrying handle using a 4mm allen Repair or replace wrench 9 With connector J1 disconnected from the 3 Using a crescent wrench carefully remove P C Board carefully apply the 12 VDC supply the plastic nut from around the pressure tothe electrode solenoid positive to Plug regulator located on the top of the machine J1 Pin 44 and Negative to Pin 43 The elec 4 Using a mm nut driver remove the case trode solenoid should activate Listen for the wraparound solenoid action in the torch handle If the NE acer solenoid does not activate it may be faulty Perform the Capacitor Discharge Replace See Figures 10 amp 11 spas Discharge 3 6 Remove Plug J1 Lead 2 and Lead 3 from the Main Inverter Board See Figure F 10 Return to Section TOC Return to Master TOC PRO CUT 25 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2
18. 9399191 114110 MS 8345 1 105 105 Purge Switch 12VDC Air Solenoid 1 UNS 235 DS gt Lo al Display LED s Output Control Control Board Solenoid 2 GENERAL DESCRIPTION The PRO CUT 25 is an inverter based constant current continuous control plasma cutting power source The control system has a safety mechanism to insure that the nozzle and electrode are in place before cutting or gouging The PRO CUT 25 initiates the plasma arc with a simple yet reliable touch start mechanism This system eliminates many of the prob lems associated with hi frequency type start systems INPUT LINE VOLTAGE AND AUXILIARY TRANSFORMER The single phase input power of 115 230 Volts AC is connected to the machine via an input cord to a switch located on the front panel The PRO CUT 25 Input voltage board automatically reconnects the auxiliary and inverter connections to configure the machine for either a low 115V AC or high 230V AC input voltage The auxiliary transformer develops the appropriate AC voltages to operate the cooling fan the control board and the inverter board NOTE Unshaded areas of Block Logic Diagram are the subject of discussion PRO CUT 25 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O o Fle
19. AC waveform frequency is between 45 and 65 Hz RMS voltage of the AC waveform is always greater than 208VAC for 115 VAC input divide these values in half The following Lincoln engine drives meet these condi tions when run in the high idle mode Ranger 200 amp 250 engine drives Commander 300 400 amp 500 engine drives Some engine drives do not meet these conditions eg Miller Bobcats etc Operation of the PRO CUT 25 is not recommended on engine drives not conforming to these conditions Such combinations may overvoltage the PRO CUT 25 power source GAS INPUT CONNECTIONS Supply the PRO CUT 25 with clean compressed air or nitrogen Supply pressure must be between 80 psi and 150 psi Flow rate should be approximately 4 0 113 NOTE Oil in the air supply to the PRO CUT 25 can cause severe problems Use only a clean air supply Compressed gas be supplied either through the air fitting supplied with the machine or through the 4 19 BSPP thread at the rear of the machine To use the air fitting supplied with the machine packaged in the con sumable kit apply teflon tape to the fitting threads and install the fitting in the port at the rear of the machine If compressed air is being used it is highly recom mended that an inline filter be installed in the air sup ply line ahead of the air connection to the PRO CUT 25 standard nominal 5 micron inl
20. Return to Section TOC Return to Master TOC Return to Master TOC F 25 TROUBLESHOOTING amp REPAIR TORCH CONTINUITY AND SOLENOID TEST 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 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 troubleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION This procedure will help the technician determine if the torch cable consumables and elec trode solenoid are functioning properly MATERIALS NEEDED Volt Ohmmeter 12 VDC 1 Amp Power Supply 7mm Nut Driver 4mm Allen Wrench Crescent Wrench PRO CUT 25 LINCOLN 5 F 25 TEM TROUBLESHOOTING amp REPAIR dd TORCH CONTINUITY AND SOLENOID TEST continued FIGURE F 10 A Return to Section Return to Master TOC LEAD 2 NZL gt WRK gt LEAD 3 EL gt Plug J1 gt Harness Plug 0 Return to Master TOC lectrode is insulated from Brass Body Electrode Lead EL 3 Connector 3 center o 2 2
21. 2 5 TROUBLESHOOTING 8 REPAIR TORCH CONTINUITY AND SOLENOID TEST continued TABLE F 1 TORCH ASSEMBLY RESISTANCES TEST CIRCUIT S BEING EXPECTED TEST POINTS TESTED RESISTANCE CONDITIONS Lead 2 Pilot arc 1 5 ohms maximum Torch consumables To Lead 3 leads in place Lead 2 to Torch Pilot arc lead to 1 0 ohm maximum Torch consumables Nozzle nozzle in place Lead 8 to Torch Pilot arc lead to 1 0 ohm maximum Torch consumables Nozzle nozzle in place Pin 1 to Pin 2 Torch trigger circuit 100K ohms minimum Torch trigger NOT Plug J1 Red Leads pulled not activated Pin 1 to Pin 2 Torch trigger circuit 1 0 ohm maximum Torch trigger pulled Plug J1 Red Leads activated Pin 3 to Pin 4 Electrode Solenoid 45 to 55 ohms None Plug J1 Gray Leads Figur LEAD 2 NZL gt WRK 2 LEAD 3 EL gt 4 3 2 1 Harness Plug J1 e F 11 10 Torch circuits may be measured when elec 11 Replace leads and plugs previously trode and nozzle place if the various cir removed cuits are isolated from each other NZL 2 5 5 Electrode 3 Trigger 1 2 and Torch leads 3 4 9 should all measure greater than 1 Meg ohm when 2 2 checked as isolated circuits See Figure 10 G2 Diagram PRO CUT 25 LINCOLN 5 F 28 NOTES LINCOLN 5 O N gt o oc 901 Je1Se A 0 9
22. E gt 212 5 5 Return to Section TOC Return to Master TOC Return to Master TOC P TROUBLESHOOTING amp REPAIR F 5 TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS The machine powers up properly but there is no response no air flow or pilot arc when the torch trigger is pulled Only the power LED is lit Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S FUNCTION PROBLEMS Make sure the torch handle or cable is not damaged or pulled from the machine Replace if necessary Make sure the air supply is converted and operating properly RECOMMENDED COURSE OF ACTION Check all connectors and wires for loose or faulty connections See Wiring Diagram Perform thel Air Gas Solenoid Test The control board may be faulty Replace The machine powers up properly but only air flows when the torch trigger is pulled no pilot arc is established Make sure the torch consum ables are in place and in good condition Replace if neces sary 2 Set air pressure at 65psi Make sure there are no kinks or restrictions for air flow in the torch cable Make sure that the correct size nozzle is being used Must be a 028 orifice Pro Cut 55 size nozzles will not work with the Pro Cut 25 system Check all connectors and wires for loose or faulty connections See Wiring Diagram Per
23. R24 5 Q2a b c 6 8k 5W IRG4BC30W shunt cial gu SHe CN2 9 19 5 6 3 e 241 Main Inverter Board Solenoid 2 rir Input Voltage Board 1516121814 1 11 4 137 19242123 8 14 1 2 3 4 no 9 2 ER o ISI Iso ele PREP aE EEE 5 19 8 6179 3 t 2 18147 154 115 16101213 23222 8 CNT 12 0 Air Display LED s Purge Solenoid Switch 1 Output Control Control Board MAIN TRANSFORMER O o Fle S PEN 2 2 8 mlt 5 2 1 The pair of IGBTs act as a switch assembly This assembly feeds a primary winding of the main trans former When current is pulsed through this primary winding a resultant current is produced on the sec ondary winding of the main transformer The DC cur rent flow through the primary winding is redirected or clamped back to the filter capacitors when the IGBTs are turned off This is needed due to the inductance of the transformer primary winding The primary current also passes through the current transformer which sends a signal to the control cir cuits of the inverter board This signal and the control circuits limit the maximum primary current flow through the IGBTs The pair of IGBT s are fired at 15 microsecond intervals creating a constant 66 6KHz output The secondary portion of the main trans
24. ret Ee o B 5 DISCUSS e EET B 6 Procedure Recommendations B 7 ck B 7 Suggestions For Extra Utility From The Pro Cut B 7 Section Section D Theory of Section E Troubleshooting and Section F How to Use Troubleshooting etie tet Re itti ike Ee a EDS F 2 Troubleshooting F 4 est MOCCOULCS osuere RU eT 9 Replacement Proced res F 29 Electrical Section G Parts Manual Pro Cut 25 P 357 Series EEEa Aasaia raana P 210 U PRO CUT 25 LINCOLN 5 iv NOTES PRO CUT 25 LINCOLN 5 901 Je1Se A 0 901 Je1Se A 0 901 J91Se N 01 901 J91Se N 01 Section A 1 TABLE OF CONTENTS Section A 1 INSTALLATION SECTION 1i Installation 2 Technical Specifications ee eter ter ere A 2 E E Safety ProcaUtiOn
25. 390k 10k 220 Celle Ligure SV Italia olo cee 10u Mte Pro Cut 25 Control Board o 165 50 Hybrid 1 Size Document Number TS ENABLE amp TURN OFF DELAY 83 99039 0 r pese Tuesday Apri 13 1999 Breet OF 3 5 4 2 1 5 5 PRO CUT 25 e ELECTRICAL DIAGRAMS 6 6 SCHEMATIC CONTROL PRINTED CIRCUIT BOARD SHEET 3 e E 5 2 5 4 3 2 1 Slo gs Hybrid Hybrid 1 Hybrid 2 Hybrid 1 12V_IN 12V_IN 58 3 5 uns es uus es e s gt R200 R201 R206 R212 R217 2 2k XZ 12 2 2k 22k 7 12 22k 95134 D512A D W 0201 9203 D 1 85807 BC807 XZ N7 R18 55128 R40 05138 22k 15 9200 9202 80438 BD438 7 31 3 a PRESSURE SV 7 SAFETY LD 0 28 2 2k SAFETY LO 22 49 THERMAL LED JPe 1 2 3 4 4 5 6 7 8 2 5 n o 3 4 5 6 7 8 9 10 12 13 14 15 16 17 R105 R202
26. 5 F 22 1 LEAD 2 NZL Using a crescent wrench LEAD 3 EL TROUBLESHOOTING amp REPAIR F 22 MAIN INVERTER BOARD VOLTAGE TEST CONTINUED TEST PROCEDURE Remove input power to the PRO CUT 25 machine Remove carrying handle using a 4mm allen wrench carefully remove the plastic nut from around the pressure regulator located on the top of the machine Using a 7mm nut driver remove the case wraparound Perform the Capacitor Discharge Procedure detailed earlier in this section Visually check for burned or damaged components on the input board If any components are physically damaged or determined to be faulty except the fuse the input board should be replaced 7 10 Apply the correct input power to the Pro Cut 25 machine 115VAC or 230VAC Carefully test for approximately 300VDC at the P1 bridge terminals See Figure F 8 This represents the rectified voltage supplied from the input board See the Wiring Diagram Carefully test for approximately 15VAC at the test points on bridge P2 This is the control supply voltage from the input board See Figure F 8 See the Wiring Diagram Carefully test for 12VDC at test points C17 See Figure 8 See Wiring Diagram This is the rectified and regulated DC supply voltage for the inverter board control circuitry Figure F 8 Test Points P2 WRK Plug J1 Harness Plug RIGHT SIDE OF MACHINE PRO
27. Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours 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 Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher met allique 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 Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonc tionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 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 enrouler le c ble lectrode autour de n importe quelle partie du corps Un coup d arc peut tre plus s v re qu un coup de soliel donc a Utiliser un bon m
28. m Celle Ligure SV Italia 2 9 HEADER SX me 2 Pro Cut 25 Control Board 9 gt Document Number 99039 0 2 pese Tuesday Apri 13 1999 Breet 3 3 e c 5 4 3 2 1 51 3 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN PRO CUT 25 ae ELECTRICAL DIAGRAMS ae PC BOARD ASSEMBLY MAIN INVERTER BOARD Codice Descrizione W7900006 SIGILLANTE SILICONICO W7900010 VERNICE ISOLANTE 220 0799084 ADESIVO PER INVERTER Return to Section TOC Return to Master TOC N J COUT u cx W7004400 REV 2 SPECIFICHE DI COLLAUDO 006 Return to Master TOC Return to Section TOC ESEGUIRE LE PROCEDURE DI COLLAUDO 006 N B APPLICARE SILICONE RIF 1 INTO
29. 100 Duty Cycle Output Current Range Maximum Open Circuit Voltage 400 Volts Pilot Current Functional Test 1 Connect the machine to 230VAC and air supply 70psi minimum 2 Turn on machine and verify the following When the machine is turned on the Thermal LED turns on for approximately 1 second The fan is functional The power LED is lit 3 Test the pressure switch in the following way Press and hold the Purge button on the front of the machine Using the regulator on the machine slowly lower the air pressure and verify that the gas pressure LED turns on at approximately 35 to 40 psi With the gas pressure LED on release the Purge button and then pull the trigger on the torch Verify that a pilot arc does NOT occur Release the trigger While again pressing the Purge button slowly increase the air pressure using the regulator on the machine until the gas pressure LED turns off Verify that the LED turns off at approximately 40 45 psi Continue to press the Purge button and set the air pressure at 65psi Release the Purge button gt Test the Purge button safety function by again pressing the Purge button and then pulling the trigger on the torch Verify that a pilot arc does NOT occur Release the trigger and the Purge button This is not a repeat of the previous step in this step the Purge button is pressed and the gas pressure LED is off a With no air flowing postflow pull the trigger on th
30. 18k 680 10k 10k 10k 19 cis 16 lu 10u CFS 104 5 9 125 50 lt gt 125 50 PILOT ARC TRANSFER PILOT ARC TIME LIMIT OCV DETECT OCV TIME LIMIT Fie 5 912 FER 5 _______ Hybrid 1 RTI c ol 05084 ER gg OPREFLOV 5 5 2 8V D4 tj sorse D508B 2 9 bd PURGE TS evi 10 33 37 A Dei U4B Dee R55 OPURGE MS MS MAIN SOLENOID 32 48 v 20106 770 TS TORCH SOLENOID SAFETY CHK TRANSFER SW t 54 DEFAULT CAPACITOR 100n 257 PURGE lt LOW PURGE gt DEFAULT CAPACITOR VOLTAGE 16V TRANSFER 6 DEFAULT DIODE BAS32L Vouto gt Reo DEFAULT ZENER DIODE 2 2 4 TS DRIVER 47 47 DEFAULT RESISTOR 1 8 1 DVLOAD 9 wW DEFAULT TRANSISTOR 8 817 25 TPL O LL oTe DEFAULT SCR MCROBBT1 O ORTICW 7 31 ORTICCV V PRESSURE SW 5 0193 5142745 LOW ERREOR PBNO Lincoln Electric Italia s r l el 14 27 Celle Ligure SV Italia 2 2 ces me 2 e Pro Cut 25 Control Board o gt 5 NV Size Document Number o E 1 25 50 99039 2 pese Tuesday Apri 13 1999 Breet T OF 3 5 4 2 1 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LI
31. 2 Return to Section Return to Master TOC Q 2 5 ELECTRIC SHOCK can kill e 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 e Prior to performing preventative maintenance perform the following capacitor discharge procedure to avoid electric shock DISCHARGE PROCEDURE 1 Remove input power to the PRO CUT 25 machine 2 Remove carrying handle using a 4mm allen wrench 3 Using a crescent wrench carefully remove the plastic nut from around the pressure regulator located on the top of the machine 4 Using a 7mm nut driver remove the case wraparound 5 Be careful not to make contact with the capacitor terminals located at the top of the main inverter Board 6 Obtain a high resistance and high wattage resistor 25 1000 ohms and 25 watts minimum This resistor is not supplied with machine NEVER USE A SHORTING STRAP FOR THIS PROCEDURE 7 Locate the eight capacitor terminals located at the top rear of the main inverter board See Figure F 1 8 Use electrically insulated gloves and insulated pli ers 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 9 Repeat
32. 3 EMF Cutting or gouging current creates EMF N fields around torch cables and cutting machines 8 b EMF fields may interfere with some pace makers so operators having a pacemaker should consult their physician before cutting or gouging 8 c Exposure to EMF fields during cutting or gouging may have other health effects which are now not known 8d All operators should use the following procedures in order to minimize exposure to EMF fields from the cutting or gouging circuit 8 d 1 Route the torch and work cables together Secure them with tape when possible 8 d 2 Never coil the torch cable around your body 8 d 3 Do not place your body between the torch and work cables If the torch cable is on your right side the work cable should also be on your right side 8 d 4 Connect the work cable to the workpiece as close as possible to the area being cut or gouged 8 d 5 Do not work next to cutting power source Apr 93 LINCOLN 8 Return to Master TOC Return to Master TOC Q 2 5 Return to Master TOC iii SAFETY PRECAUTIONS DE SURETE Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans manuel aussi bien que les pr cautions de s ret g n rales suiv antes Sdret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique
33. Return to Section TOC Return to Master TOC Return to Section TOC O10 E E 2 212 5 5 ply ojo Return to Section TOC Return to Master TOC Return to Master TOC F 6 Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS The cutting arc starts but sputters badly POSSIBLE AREAS OF MISADJUSTMENT S FUNCTION PROBLEMS Make sure the operating proce dure is correct for the process See the Operation section of the manual Make sure the work clamp is connected tightly to the work piece Make sure the torch consum able parts are in place and in good condition Replace if necessary Make sure the air pressure is set at 65psi Make sure the air supply is not contaminated with oil or excessive water TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE F 6 RECOMMENDED COURSE OF ACTION 1 The control Check all connectors and wires for loose or faulty con nections See Wiring Diagram Perform the Torch Continuity and Solenoid Test Perform the Resistance board may be faulty Replace Use the correct extension cord See the instruction manual The pilot arc is normal but the arc will not transfer to the work piece Make sure the operating procedure is correct for the process See section of the manual Make sure the work clamp is connec
34. gt R203 gt R204 gt R205 R207 gt R208 gt R209 gt R210 Hybrid 3 gt R214 gt 825 R216 R218 gt R219 gt R220 gt Reel 82 82 82 82 560 560 560 560 82 82 82 82 560 560 560 560 als 59 3 2 7 118 Display Board I E POWER LED S pss GAS LED S THERMAL LED S SAFETY LED S E o LDD LDD LD3B LD3D LD4D 1046 LD5B LDSD LD6D 1066 LD7B 1070 gt LD8D E O HLMP 2550 HLMP 2550 HLMP 2855 HLMP 2855 HLMP 2450 HLMP 2450 HLMP 2755 HLMP 2755 HLMP 2450 HLMP 2450 HLMP 2755 HLMP 2755 HLMP 2350 HLMP 2350 HLMP 2655 HLMP 2655 9 5 wo n e n N s LDIA w LDIC LDA LDSA LD3C LD4A LD4B LDSA w LDSC 4 LD A LD6B LD7A w 1076 LD8A 1088 HLMP 2550 HLMP 2550 HLMP 2855 HLMP 2855 HLMP 2450 HLMP 2450 HLMP 2755 HLMP 2755 HLMP 2450 HLMP 2450 HLMP e755 HLMP 2755 HLMP 2350 HLMP 2350 HLMP 2655 HLMP 2655 x E ES E n E JP2 O O LED3 1 2 oLED4 3 4 5 6 Lincoln Electric Italia s r l
35. 0 2 Main Inverter Board Solenoid 2 2 Input Leave od Voltage Board 1816121814 1 114 137 19242123 8 1 1 2 3 4 T 1 17 5 lt 5 lt 0 612 I Elle og 5 5 2 52 elle lt o le m gt 1 3 4 ag 8 179 3 1 218147 154 115 16101213 23222 i 12VDC H 1 Display LED s Air ped Purge Solenoid Switch 1 o Output Control 5 Control Board o 5 c PRO CUT 25 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 8 2 gle 5 Return to Section TOC Return to Master TOC E 2 INPUT THEORY OF OPERATION FIGURE 2 INPUT LINE VOLTAGE Q1a b c IRG4BC30W D10 Lout HE E 2 WORK CLAMP Sees 026 1500uF 250V 115 230 1 50 60 VAC 15K 3W 15K 3W ar 5 Input Voltage Board 1800uF 250V 4 Q2a b c IRG4BC30W SHUNT 12VDC TRANSFER RL1 R24 6 8k 5W 13 SH SH MS 20 21 MS A8 GND 935 0 01 0 345
36. 5 ojo Return to Section TOC Return to Master TOC Return to Master TOC F 30 TROUBLESHOOTING amp REPAIR F 30 AIR GAS SOLENOID TEST continued FIGURE F 12 AIR SOLENOID Air Solenoid LEFT SIDE OF MACHINE TEST PROCEDURE Remove input power to the PRO CUT 25 machine Remove carrying handle using a 4mm allen wrench Using a crescent wrench carefully remove the plastic nut from around the pressure regulator located on the top of the machine Using a 7mm nut driver remove the case wraparound Perform the Input Capacitor Discharge Procedure detailed earlier in this section Locate the air solenoid and leads Carefully remove the two leads from the Solenoid See Figure F 12 C4 700000070 20000000 lo 7 Check coil resistance of the solenoid the two terminals Normal resistance is approximately 13 ohms If the resistance is abnormal the Solenoid may be defective 8 Carefully apply the 12 VDC supply to the solenoids lower two terminals With proper air pressure applied the solenoid should activate and air should flow from the torch nozzle If the solenoid activates but air does not flow check for a restriction in the air line or torch 9 Reinstall the two leads previously removed PRO CUT 25 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC ojo E gt 212
37. 5 5 Return to Section TOC Return to Master TOC Return to Master TOC F 36 TROUBLESHOOTING amp REPAIR INPUT BOARD REMOVAL 8 REPLACEMENT continued FIGURE F 16 Input Board Location Input Board PROCEDURE 1 Remove input power to PRO CUT 25 6 Note the orientation of the input board to avoid confusion during 2 Remove carrying handle using a reassembly 4mm allen wrench 7 Carefully label and remove cooling fan 3 Using a crescent wrench carefully leads from Input Board Pliers may be remove the plastic nut from around the necessary pressure regulator located on the top of the machine 8 Remove harness plug from lower right hand corner of board Pliers may be 4 Using a 7mm nut driver remove necessary the case wraparound 9 Directly above the harness in step 8 5 Perform Capacitor Discharge Procedure there are four leads CP 2 and AC 2 Label these leads and remove Pliers may be necessary CAUTION 10 Using a 7mm nut driver remove the two leads from terminals A and B on the Be sure to follow the recommended static free input board NOTE The lead posts on methods for handling printed circuit boards the Input Board are labeled with an Failure to do so can result in permanent damage to label the lead wires men accordingly upon removal Be careful not to misplace washers when bolts are removed PRO CUT 25 LINCOLN 5 dud
38. 5 5 ajo Return to Section TOC Return to Master TOC Return to Master TOC 31 TROUBLESHOOTING amp REPAIR CONTROL BOARD REMOVAL AND REPLACEMENT 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 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 troubleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION The following procedure will aid the technician in removing the control board for maintenance or replacement MATERIALS NEEDED Crescent Wrench Small Flathead Screwdriver 7mm Nut Driver 6mm Nut Driver 4mm Allen Wrench 2 5mm Allen Wrench Needle Nose Pliers PRO CUT 25 LINCOLN 5 F 31 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 Return to Section Return to Master TOC 2 5 TROUBLESHOOTING amp REPAIR rese CONTROL BOARD REMOVAL AND REPLACEMENT continued FIGURE F
39. LEAD 2 NZL WRK LEAD 3 EL Plug J1 Harness Plug D1 D2 amp D3 PRO CUT 25 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 Return to Section Return to Master TOC Q 2 5 TROUBLESHOOTING 8 REPAIR MAIN INVERTER BOARD RESISTANCE TEST continued 10 Remove the torch consumables Shield 12 With the Torch Consumables removed test cup Nozzle and Electrode the snubber diodes D8 and D9 See the Wiring Diagram See Figure F 5 11 With the Torch Consumables removed test the output diodes D10 and D11 See the 13 Replace the torch consumables Wiring Diagram previously removed Check the resistance across output diode D11 The resistance should be very low near or at zero ohms This verifies that the pilot arc circuit is complete See the Wiring Diagram Figure F 5 LEAD 2 NZL WRK LEAD 3 EL Plug J1 Harness Plug RIGHT SIDE OF MACHINE PRO CUT 25 LINCOLN 5 F 16 NOTES LINCOLN 5 O N gt o oc 901 Je1Se A 901 Je1Se A 0 901 J91Se N 01 901 J91Se N 0 16 DOL DOL uonoes uumeg DOL DOL ad TROUBLESHOOTING amp REPAIR T INPUT BOARD VOLTAGE TEST Retu
40. Tighten terminal wire clamp screws securely PRO CUT 25 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC E st olg 2 212 5 5 Return to Section Return to Master TOC Return to Master TOC INSTALLATION a WARNING Failure to wire as instructed may cause personal injury or damage to equipment be installed or checked by an electrician or qualified person only Use of normal 20 amp household breakers may result in over current trips If breaker trips occur reduce the cutting current output until nuisance trips stop To achieve the full 25 amp output capability of the machine with 115 VAC input remove the 15 amp or 20 amp plug on the input cord and install a 30 amp or 50 amp plug designed for 115 VAC NEMA style 5 30P or 5 50P Follow the instructions included with the plug Connect to an appropriate branch circuit with a mating receptacle The PRO CUT 25 performs best when connected to 230VAC inputs To change over to 230VAC operation install a 230VAC plug with a current rating equal to or greater than 20 amps For use on engine drives keep in mind the above input draw restrictions and the following precaution The PRO CUT 25 can be operated on engine driven generators as long as the 230 volt auxiliary meets the following conditions AC waveform peak voltage is below 400 volts
41. bd Control is from control bd 45 to 55 ohms Schematic 98044 8v open trigger to vi Detail PIP safety ckt 8 Sp 6v output Input bd 12v pilot M 0 cutting 420 Vde for NO parts in place pip 6 Vde with parts IN 12 VDC sw supply is used for 1 Output control control amp its ref bd invert 2 Shunt feedback invert 3 Transfer relay invert amp control 4 Torch solenoid inv amp control 5 LED supply 8 VDC supply is used for 1 Turn on PWM invert 2 PIP detect ckt control 3 Pilot arc timer control 4 Purge ckt button control 5 Drivers for LED logic control 6 Torch solenoid logic ckt control 7 Air solenoid logic ckts amp driver control 8 Transfer relay invert Logic amp driver control This bd generates 8 which get its input from the inverter bd via the 12 on the inverter bd 8v is used on both bds PRO CUT 25 ELECTRICAL DIAGRAMS G 4 SCHEMATIC CONTROL PRINTED CIRCUIT BOARD SHEET 1
42. good safe operating condition Replace damaged insulation 1 g Never dip the torch in water for cooling or plasma cut or gouge in or under water 1 h When working above floor level protect yourself from a fall should you get a shock 1 1 Operate the pilot arc with caution The pilot arc is capable of burning the operator others or even piercing safety clothing 1 Also see Items 4c and 6 ARC RAYS can burn 2 a Use safety glasses and a shield with the prop er filter and cover plates to protect your eyes from sparks and the rays of the arc when performing or observing plasma arc cutting or gouging Glasses headshield and filter lens should conform to ANSI Z87 standards 2 5 Use suitable clothing including gloves made from durable flame resistant material to protect your skin and that of your helpers from the arc rays 2 c 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 FUMES AND GASES can be dangerous 3 a Plasma cutting or gouging may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When cutting or gouging keep your head out of the fumes Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When plasma cutting or gouging on lead or cadmium plated steel and other metals or coatings which produce hig
43. terminal will allow the IGBT to conduct and supply current to circuit components coupled to the source Current will flow through the conducting IGBT to downstream components as long as the positive gate signal is present This is similar to turning ON a light switch FIGURE E 5 IGBT BODY REGION POSITIVE VOLTAGE APPLIED BODY REGION n DRAIN DRIFT REGION n DRAIN DRIFT REGION C ter aven z TT eca Laver DRAIN DRAIN A PASSIVE B ACTIVE PRO CUT 25 LINCOLN 5 Section F 1 Section F 1 TABLE OF CONTENTS 9 TROUBLESHOOTING 8 REPAIR SECTION 5 Troubleshooting amp Repair Section Section F How to Use Troubleshooting Guide iii 2 PC Board Troubleshooting Procedures and Replacement F 3 E E Troubleshooting Guide F 4 Test Procedures Input Filter Capacitor Discharge Procedure ss F 9 Main Inverter Board Resistance Test F 11 Input Board Voltage est ii ete rrt aceite inpr F 17 Main Inverter Board Voltage Test F 21 Torch Continuity and Solenoid Test F 25 Air Gas Solenoid Test cote aet xp vta ka Pene Xx F 29 Replacement Procedures Control Board Removal and Replacement 31 5 Input Board Removal and F 35 9 Main Inverte
44. the duty cycle and output rating If excessive operating temperatures should occur the thermal status indicator will turn on and the thermostat will prevent output voltage or current The thermal protection devices are self resetting once the machine cools sufficiently If the shutdown was caused by excessive output or duty cycle and the fans are operating normally the power switch may be left on and the reset should 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 After a thermal overload occurs and the machine resets it may be necessary to activate the torch trigger twice before a pilot arc will be initiated This is a safety precaution to eliminate accidental pilot arc initiation when the thermal protection self resets ACCIDENTAL OPERATION PROTECTION The PRO CUT 25 has two protection circuits to eliminate accidental pilot arc initiation These two circuits operate when the machine is first turned on and after a thermal overload occurs In these cases the first time the torch trigger is activated nothing will happen The torch trigger must be activated a second time before pilot arc initiation occurs This protection is added in case the machine is turned on and the trig ger is already activated or if a thermal overload self resets and the trigger is activated SAFETY PARTS IN PLACE PROTECTI
45. 01 Je1Se A 0 901 01 901 J91Se N 0 28 DOL DOL uonoes DOL uonoes DOL dii TROUBLESHOOTING amp REPAIR di AIR GAS SOLENOID TEST 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 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 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 1 888 935 3877 DESCRIPTION This procedure will help the technician determine if the solenoid is functioning properly Return to Section TOC Return to Master TOC MATERIALS NEEDED 4mm Allen Wrench 7mm Nut Driver 12 VDC Q 3 Amp Power Supply Volt Ohmmeter Crescent Wrench E i olg iz 8 mlt 5 5 Return to Section TOC Return to Master TOC PRO CUT 25 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC O10 E 2 212 e gt 5
46. 13 CONTROL BOARD LOCATION Control Board PROCEDURE 1 Remove input power to the PRO CUT 25 machine 5 Perform Capacitor Discharge Procedure 2 Remove carrying handle using a 4mm allen 6 Using a very small flathead screwdriver or a thin wrench knife blade carefully remove the red plastic cap from the front of the plastic OUTPUT knob located 3 Using a crescent wrench carefully remove the on the front of the machine See Figure F14 plastic nut from around the pressure regulator located on the top of the machine 4 Using a 7mm nut driver remove the case wrap around FIGURE F 14 SMALL RED CAP REMOVAL Small Red Cap PRO CUT 25 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 Return to Section Return to Master TOC 2 5 F 33 TROUBLESHOOTING amp REPAIR F 33 CONTROL BOARD REMOVAL AND REPLACEMENT continued 7 Anut is located under the red plastic piece that you previously removed Loosen this nut with a 6mm nut driver and remove Plastic alignment spacer may come off with knob 8 Next to the knob is a Red button that reads PURGE Remove it by gently pulling FIGURE F 15 CASE FRONT SCREW REMOVAL 3 Screws CAUTION Be sure to follow the recommended static
47. 5 LINCOLN 5 p TROUBLESHOOTING amp REPAIR Pad FAN REMOVAL AND REPLACEMENT continued 7 Using a phillips head screwdriver remove the four mounting screws on the four corners of the fan The fan will become free Return to Section TOC Return to Master TOC 8 After replacement of the fan replace the four mounting screws located at the corners of the fan 9 Reconnect labeled leads to the top of the fan Be sure to replace leads in their proper positions 10 Replace the case wraparound Ti Replace the plastic nut from around the pressure regulator Do Not Over tighten 12 Replace the carry handle Return to Section TOC Return to Master TOC E olg 2 212 5 5 Return to Section TOC Return to Master TOC PRO CUT 25 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC olo o Fle PEN gt 5 5 2 Return to Section Return to Master TOC Return to Master TOC TROUBLESHOOTING 8 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 Machine Input and Output Input Volts Hertz Input Current Rated Output 230 1 60HZ 15 Amps 20A
48. 5 gas inlet A WARNING aged Keep cylinder away from areas where it could be damaged Never lift machine with cylinder attached Never allow the cutting torch to touch the cylinder Keep cylinder away from live electrical parts Maximum inlet pressure 150 psi OUTPUT CONNECTIONS Torch The PRO CUT 25 is sent from the factory with a 15 PCT 20 cutting torch installed Additional cutting torch es can be ordered from the K1615 series Hand held torches come with 15 or 25 cables PRO CUT 25 LINCOLN 5 A 6 NOTES LINCOLN 5 O N gt o oc 901 Je1Se A 901 Je1Se A 0 901 J91Se N 01 901 J91Se N 0 DOL DOL uonoes uumeg DOL DOL Section B 1 Section B 1 TABLE OF CONTENTS o OPERATION SECTION 5 ene EN M Section B 2 aa E US B 2 2 Preheating Temperature 2 c User AS DOS DIR B 3 Op rationalFeatures and 3 Design Features and B 3 Cutting B 4 Consumabl B 4 LIMITATIONS E
49. 5 5 mation Reduce the current if desired to reduce the 9 e kerf cut width heat affected zone or travel speed ao 2 as required Keep moving while cutting Cut at a steady speed 1 Maximum output requires a 30 amp input circuit and breaker Refer to the without pausing Maintain the cutting speed 50 that Technical Specifications for proper input circuit guidelines the arc leg is 10 to 20 behind the travel direction PRO CUT 25 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC ojo O10 E gt 212 5 5 ajo Return to Section TOC Return to Master TOC Return to Master TOC ais 5 15 Leading Angle gt Direction of Travel Y L ie 10 po Arc Lag Use 5 15 leading angle in the direction of the cut Finish the cut to be made and release the trigger 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 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 frequently If the S
50. AFETY LED lights 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 over tighten 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 System 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 elec trode is approximately 062 A green and erratic arc will indicate definite electrode failure and 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 turning the power switch OFF and then ON again It is possi ble for electrical noise to trip the safety circuit on rare occasions This should not be a regular occurrence If the machine does not reset or continues to trip A WARNING ELECTRIC SHOCK CAN KILL As Turn off machine at the disconnect switch on the front of the machine before tightening cleaning or replacing consumables consult the Troubleshooting Section Use the proper cutting procedures referred to in Procedure Recommendat
51. AIR F 40 MAIN INVERTER BOARD REMOVAL amp REPLACEMENT continued FIGURE F 18 MAIN INVERTER BOARD REMOVAL Return to Section TOC Return to Master TOC o 2 5 2 3 2 PROCEDURE 15 Remove input power to PRO CUT 25 6 Locate the Main Board all associated S leads and plug connections 2 Remove carrying handle using a 6 5 4mm allen wrench 7 Label the leads and note their positions 9 8 for reassembly 2 8 Using a crescent wrench 218 carefully remove the plastic nut from 8 Using a 7mm Nut driver remove the around the pressure regulator located four nuts and washers located at the 5 on the top of the machine corners of the main board This will cc allow you to gently manipulate the board 4 Using a 7mm nut driver remove for labeling and removal of all Leads the case wraparound 9 Remove the two harness plugs from 5 Perform Capacitor Discharge front top corner of board Label and remove the four single leads from the rear top corner of board Carefully remove NZL WRK and EL leads from CAUTION lower front of board Also remove harness plug J1 Be sure to follow the recommended static free methods for handling printed circuit boards 10 Remove board Failure to do so can result in permanent damage to the equipment Return to Section TOC Return to Master TOC PRO CUT 25 LINC
52. CUT 25 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 Return to Section Return to Master TOC o 2 5 TROUBLESHOOTING amp REPAIR MAIN INVERTER BOARD VOLTAGE TEST CONTINUED 10 Carefully test for 12VDC at test points 12 Carefully check for the presence of C7 See Figure 9 See the Wiring 8VDC at C19 test points If not correct Diagram This is the rectified and the control board or associated wiring regulated supply for the pulse width may be faulty See Figure 9 modulation circuit See the Wiring Diagram 11 Carefully test for 12VDC at C18 test points If it is not correct the control board or associated wiring may be faulty See the Wiring Diagram See Figure Figure F 9 Test Points P2 LEAD 2 NZL WRK LEAD 3 EL Plug J1 Harness Plug RIGHT SIDE OF MACHINE PRO CUT 25 LINCOLN 5 F 24 NOTES LINCOLN 5 O N gt o oc 901 Je1Se A 0 901 Je1Se A 0 901 01 901 J91Se N 0 24 DOL DOL uonoes DOL uonoes DOL Return to Section TOC Return to Master TOC Return to Section TOC E olg 2 212 5 5
53. For additional safety information it is strongly recommended that you pur chase a copy of Safety in Welding amp Cutting ANSI Standard 249 1 from the American Welding Society Box 351040 Miami Florida 33135 CSA Standard W117 2 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS ELECTRIC SHOCK can kill 1 The electrode and work or ground circuits are electrically hot when the power source is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insu late hands 1 0 When the power source is operating voltages in excess of 250 volts are produced This creates the potential for serious elec trical shock potentially even fatal 1 c Insulate yourself from work and ground using dry insulation When cutting or gouging in damp locations on metal frame work such as floors gratings or scaffolds and when in posi tions such as sitting or lying make certain the insulation is large enough to cover your full area of physical contact with work and ground 1 d Always be sure the work cable makes a good electrical con nection with the metal being cut or gouged The connection should be as close as possible to the area being cut or gouged 1 e Ground the work or metal to be cut or gouged to a good elec trical earth ground 1 f Maintain the plasma torch cable and work clamp in
54. LECT PROPER LOCATION Place the PRO CUT 25 where clean cool air can freely circulate in and out the side louvers Dirt dust or any foreign material that can be drawn into the machine should be kept at a minimum Failure to observe these precautions can result in excessive operating temper atures and nuisance shutdown of the machine A source of clean dry air or nitrogen must be supplied to the PRO CUT 25 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 4 0 cfm 113 l min Failure to observe these pre cautions could result in excessive operating tempera tures or damage to the torch STACKING The PRO CUT 25 cannot be stacked TILTING The PRO CUT 25 must be placed on a stable level surface so it will not topple over HIGH FREQUENCY INTERFERENCE PROTECTION The PRO CUT 25 employs a touch start mechanism for arc initiation which 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 high frequency interference into the Pro Cut can be minimized 1 Make sure the power supply chassis is connected to a good earth ground The work terminal ground does NOT ground the machine frame 2 Keep the work
55. Master TOC Return to Master TOC F 9 TROUBLESHOOTING amp REPAIR INPUT FILTER CAPACITOR DISCHARGE PROCEDURE 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 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 troubleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION This procedure will drain off any charge stored in the four capacitors that are part of the Inverter Board assembly This procedure MUST be performed as a safety precaution before conducting any test or repair procedure that requires you to touch internal components of the machine MATERIALS NEEDED 4mm Allen Wrench Volt Ohmmeter 7mm Nut Driver Crescent Wrench Insulated Gloves Insulated Pliers High Wattage Resistor 25 to 1000 ohms 25 watts minimum PRO CUT 25 LINCOLN 5 F 10 F 10 TROUBLESHOOTING amp REPAIR INPUT FILTER CAPACITOR DISCHARGE PROCEDURE continued Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2
56. NCOLN PRO CUT 25 G 5 SCHEMATIC CONTROL PRINTED CIRCUIT BOARD SHEET 2 ELECTRICAL DIAGRAMS LINCOLN 5 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual e E 5 9 5 4 3 2 1 Slo 87 we TRIG 78 9 2 20 D5004 4 ben PILOT TIME s E 5 2 GAS ENABLE 18k D500B U7A R95 TIME 1 9 13 2 U4F R91 7 13 43 sw CHIGH DPEN 22 cu 09 95054 0106 560 Ree 1 CF7 R89 15 2 4 Kt 4 4 PRESSURE SW k A sis 0106 2506 Ret SAFETY LO V 42 gan 4 17 46 PREFLOW TRIGGER Os sci 55674 LM324D lt LOW PREFLOW 470n 1k 0106 15038 Re7 tpt R90 R92 R94 1k 10k 0567 10k e 270k 10k 6 D5028 C24 ha PILOT TIME ini 7585 gt 125 50 PURGE SW 12550 TRIGGER DISABLE 1506 TRIGGER INTERFACE PREFLOW TIMER Olo Di zO DVLUAD Eg 8V 8V A A 0
57. NOTES LINCOLN 5 O N gt o oc 901 Je1Se A 0 901 491590 0 901 J91Se N 01 901 J91Se N 0 38 DOL 0 uumeg DOL uonoes DOL DOL Return to Section TOC Return to Master TOC Return to Section TOC O10 E 2 212 mlt 5 5 ajo Return to Section TOC Return to Master TOC Return to Master TOC F 39 TROUBLESHOOTING amp REPAIR MAIN INVERTER BOARD REMOVAL AND REPLACEMENT 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 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 troubleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION The following procedure will aid the technician in removing the MAIN INVERTER BOARD for maintenance or replacement MATERIALS NEEDED 4mm Allen Wrench Crescent Wrench 7mm Nut Driver Needle Nose Pliers PRO CUT 25 LINCOLN 5 F 39 F 40 TROUBLESHOOTING amp REP
58. OCK CAN KILL Turn off machine at the disconnect switch on the front of the machine before tightening cleaning or replacing consumables Q_e Change consumables as required THERMAL PROTECTION Thermal Detection Devices protect the machine from excessive operating temperatures Excessive temper atures may be caused by a lack of cooling air or oper ating the machine beyond the duty cycle and output rating If excessive operating temperatures should occur the yellow thermal LED will light and the Detection Devices will prevent output voltage or cur rent These Detection Devices are self resetting once the machine cools sufficiently If the thermostat shutdown was caused by excessive output or duty cycle and the fan is operating normally the Power Switch may be left on and the reset should occur within a 15 minute peri od If the fan is not turning or the air intake louvers were obstructed then the power must be switched off and the fan problem or air obstruction must be correct ed A protection circuit is included to monitor the voltage across filter capacitors In the event that the capacitor voltage is too high the protection circuit will prevent output REPLACEMENT OF INTERNAL FUSES The PRO CUT 25 has additional protection provided to some circuits through internal fuses For replacement of those fuses proceed as follows 1 Turn off the power to the unit and remove the input plug 2 Allow the machine to stand
59. OLN 5 41 TROUBLESHOOTING amp REPAIR 41 MAIN INVERTER BOARD REMOVAL 8 REPLACEMENT continued FIGURE F 19 INVERTER BOARD LEAD LOCATIONS o 9 2 E 2 Harness plugs olo 2 5 5 0 a 2 5 5 dc 2 NZL gt WRK gt EL Harness gt mu Plug J1 o S 55 Olga 0 a gt 2 HIE 11 Reconnect all leads to the new board 14 Replace the plastic nut from around the pressure regulator Do Not Over 12 Replace the four bolts and washers tighten previously removed from the corners of the board 15 Replace the carry handle 13 Replace the case wraparound Return to Section TOC Return to Master TOC PRO CUT 25 LINCOLN 5 F 42 NOTES LINCOLN 5 O N gt o oc 901 Je1Se A 901 Je1Se A 0 901 J91Se N 01 901 J91Se N 0 42 DOL DOL uonoes uumeg DOL DOL Return to Section TOC Return to Master TOC Return to Section TOC ojo O10 E gt 212 mlt 5 5 ajo Return to Section TOC Return to Master TOC Return to Master TOC F 43 TROUBLESHOOTING amp REPAIR SWITCH REMOVAL AND REPLACEMENT Service and repair should be performed by only Li
60. ON The PRO CUT 25 has protection circuits to detect the proper connection of the torch and the proper installation of the consumables If an error is detected with either of these two items the Safety status LED will be turned on and the output of the machine will be disabled The PRO CUT 25 must be turned off and the problem must be corrected before normal operation can occur PRO CUT 25 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC ojo o E gt 212 mlt 5 5 ajo Return to Section TOC Return to Master TOC Return to Master TOC THEORY 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 current to components connected to the source The circuit 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
61. OOTING amp REPAIR INPUT BOARD VOLTAGE TEST CONTINUED TEST PROCEDURE Remove input power to the PRO CUT 25 machine Remove carrying handle using a 4mm allen wrench carefully remove the plastic nut from around the pressure regulator located on the top of the machine Using a 7mm nut driver remove the case wraparound Perform the Capacitor Discharge Procedure detailed earlier in this section Visually check for burned or damaged components on the input board If any components are physically damaged or determined to be faulty except the fuse the input board should be replaced Check fuse F1 1 amp Replace if defective 8 Apply 115VAC input to the PRO CUT 25 machine The test should be performed with 115VAC applied Not 230VAC Note If the peak input voltage is above 400VAC the thermal light may activate Reduce the input voltage Turn on the machine and carefully check for 115VAC 10 at points A and See Figure F 6 See the Wiring Diagram Note Within 4 seconds of the machine being turned on the two relays RL2 and RL3 should activate If they don t the input board is faulty Figure F 6 Input Board Description TEST POINTS 12345678 H lt PLUG PRO CUT 25 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 Return to Section
62. RNO Al CONDENSATORI COME INDICATO PER UN ALTEZZA DI 1 APPLICARE SILICONE RIF 1 SUI PIN DEL CONNETTORE J1 COPRENDOLI COMPLETAMENTE PART 1 N D APPLICARE SILICONE RIF 1 TRA LA SCHEDA PWM E I CONDENSATORI C7 E C13 COME INDICATO PER UN ALTEZZA DI 2cm N E APPLICARE SILICONE RIF 1 TRA LA SCHEDA PWM E LA SCHEDA INVERTER PER UN ALTEZZA DI 0 5cm N F ISOLARE FASTON INDICATI EL WRK E NZL IL CONNETTORE J1 E LE 2 PIZZOLE DI TERRA CON NASTRO ADESIVO COME INDICATO PART 1 2 3 N G VERNICIARE RIF 2 LA SCHEDA PER IMMERSIONE VEDERE PROCEDURA 008 PRESTANDO PARTICOLARE ATTENZIONE AFFINCHE IL LIVELLO DELLA VERNICE CORRISPONDA A QUANTO INDICATO IN PART 4 N H APPENDERE LA SCHEDA IN POSIZIONE VERTICALE VEDERE PART 5 FINO A QUANDO SMETTE DI GOCCIOLARE N APPENDERE LA SCHEDA IN POSIZIONE INCLINATA VEDERE PART 6 FINO A QUANDO RISULTA ASCIUTTA AL TATTO LASCIARE ASCIUGARE LA SCHEDA PER 24 ORE DALLA VERNICIATURA DOPODICHE FARE IL TEST DIELETTRICO N K APPLICARE L ADESIVO RIF 3 SUL LATO SALDATURE COME INDICATO IN PART 7 55 4 2 2 5 5 a a
63. Return to Master TOC Return to Master TOC O o s 7 o 9 tc Return to Master TOC View Safety Info View Safety Info 9 gt 2 gt View Safety Info RETURN TO MAIN MENU 49 PRO CUT 25 For use with machine code numbers 10661 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind However your overall safety can be increased by proper installation and thoughtful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READ ING THIS MANUAL AND THE SAFETY PRECAUTIONS CON TAINED THROUGHOUT And most importantly think before you act and be careful SERVICE MANUAL LINCOLN Copyright 2006 Lincoln Global Inc World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 1 888 935 3877 FAX 216 486 1751 WEB SITE www lincolnelectric com Return to Master TOC Return to Master TOC o 2 5 Return to Master TOC SAFETY PLASMA CUTTING or GOUGING can be hazardous PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights
64. Return to Master TOC o 2 5 iiis TROUBLESHOOTING amp REPAIR ii INPUT BOARD VOLTAGE TEST CONTINUED 10 After the relays activate check for 13 With the torch consumables in place 115VAC from both test points AC to nozzle electrode and shield check CP See Figure F 7 If this voltage is for the presence of approximately not present or low the relay contacts 6VDC at pins 3 and 4 of plug CN1 may be defective See Figure F 7 Note With the torch consumables 11 Check the fan voltage at the fan removed this voltage should be terminals V1 amp V2 See Figure F 7 approximately 26VDC Normal is 230VAC If this voltage is normal 230VAC the primary circuit of 14 If the relays RL2 and are activating the auxiliary transformer is operating with 115VAC applied to the machine correctly and the above test voltages are correct the input board is functioning correctly 12 Check for the presence of approximately 15VAC at pins 1 and 2 of plug CN1 See Figure F 7 Figure F 7 Input Board Test Points Fan Leads 12345678 PLUG PRO CUT 25 LINCOLN 5 F 20 NOTES LINCOLN 5 O N gt o oc 901 Je1Se A 901 Je1Se A 0 901 J91Se N 01 901 J91Se N 0 20 DOL DOL uonoes uumeg DOL DOL Return to S
65. TA INT W8110004 RONDELLA DENTATA INT M4 W8111004 OTTONE W8200003 DADO ACCIAIO ZINCATO M3 W8210004 DADO OTTONE 4 W84A4355 ISOLANTE ISOLCART W86A4406 TORRETTA M4x8 M M OTTONE W9108165 DISSIPATORE TRANS 10220 W1020100 RESISTENZA 10 OHM 0 25W 5 O MAINS 115 230Vac FISSARE L ISOLANTE ALLA SCHEDA CON SILICONE NO FUSE 000 1959 gt 1 2 NO Return to Section Return to Master TOC EV 02 11 2 L3 N N NO NO W FI PF2 LATO COMPONENTI 20062 SIPC25 W7005600 REV 2 8 gt 4 OV 115V 230V 11 12 98 N LINCOLN ELECTRIC ITALIA 20 m
66. TROUBLESHOOTING amp REPAIR olo INPUT BOARD REMOVAL amp REPLACEMENT continued 5 518 FIGURE 17 INPUT BOARD REMOVAL HE Switch Leads 4 E BL T Four olo LE Leads O o CP FEE Eg 515 lt a gt o Fan lade 5 3 a 4 ids Mounting Screws 2 2 5 5 O12 11 Using a 7mm Nut driver remove the 15 Reconnect the harness plug oz four mounting nuts from the corners of 8 the Input Board Be careful not to lose 16 Reconnect the fan leads to the Input E the washer behind each nut Input Board Be sure that leads are 5 Board be removed after these four connected to their original positions nuts are removed 17 Replace the case wraparound 12 After replacement of the Input Board replace the four nuts and 18 Replace the plastic nut from around the washers previously removed pressure regulator Do Not Over from the corners of the board tighten Do Not Over tighten 19 Replace the carry handle olo 13 Using a 7 mm nut driver replace e two leads originating from the sis Input Switch A B 8 14 Reconnect four leads their correct positions AC and 3a PRO CUT 25 LINCOLN 5 F 38
67. TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION Contact the Lincoln Electric Service Department 1 888 935 3877 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 Check for blown or missing fuses in the input lines and the slow blow fuse on the input board Check the input power switch for proper operation Check the leads associated with the power switch for loose or faulty connections See the Wiring Diagram 3 Check all connectors and wires for loose or faulty connections 4 Perform the Voltage Machine is malfunctioning no output no status indicator lights fans run Check the input voltage at the machine Input voltage must match the rating plate 1 Check all connectors and wires for loose or faulty connections See Wiring Diagram 2 Perform the Input Voltage Board Test The control board may be faulty Replace 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 1 888 935 3877 PRO CUT 25 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC ojo O10
68. ard to recreate the original problem a If the original problem does not reappear by substituting the original board then the PC board was not the problem Continue to look for bad connections in the control wiring harness junction blocks and termi nal strips b If the original problem is recreated by the substitution of the original board then the PC board was the problem Reinstall the replacement PC board and test the machine 6 Always indicate that this procedure was followed when warranty reports are to be submitted NOTE Following this procedure and writing on the warranty report INSTALLED AND SWITCHED PC BOARDS TO VERIFY PROBLEM will help avoid denial of legitimate PC board warranty claims Return to Section TOC Return to Master TOC PRO CUT 25 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 Return to Section Return to Master TOC 2 5 F4 TROUBLESHOOTING amp REPAIR F 4 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
69. asque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du rayon nement 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 rayonnement de l arc c Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones ou l on pique le laitier 6 Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le 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 autres circuits Cela peut provoqu
70. clamp isolated from other work clamps that have high frequency 3 If the work clamp cannot be isolated then keep the clamp as far as possible from other work clamp connections 4 When the machine is enclosed in a metal building several good earth driven electrical grounds around the periphery of the building are recom mended Failure to observe these recommended installation procedures may cause improper function of the Pro Cut or possibly even damage to the control system or power supply components INPUT ELECTRICAL CONNECTIONS The PRO CUT 25 is rated for 115VAC or 230VAC inputs and will automatically reconnect for the supplied voltage The machine is shipped from the factory for operation on 115VAC 15 amp circuits Use on 15 amp branch circuits will limit cutting output as indicated by the graphics around the output knob If the output is set at 20 amps or greater the input fuse or circuit breaker may blow in roughly 30 seconds or less depending on fuse or circuit breaker type To achieve 20 amp output with 115VAC input replace the 15 amp plug on the input cord with the supplied 20 amp plug and connect the unit to a 20 amp branch cir cuit with super lag fuses or equivalent breaker To install the supplied 20 amp plug Connect the white neutral wire under terminal clamp with silver screw and black hot wire under terminal clamp with brass screw Connect green wire under terminal clamp with green screw
71. crescent wrench These leads and their positions are not Fic carefully remove the plastic nut from labeled for you so be sure to label them 5 around the pressure regulator located accurately So on the top of the machine 9 9 After labeling the four leads remove them 4 Using 7mm nut driver remove from the switch using a flathead cle the case wraparound screwdriver 5 5 10 After replacement of the switch 5 Perform Capacitor Discharge reconnect the four leads making sure that the switch is oriented correctly and the E insulation is positioned correctly 6 Using a phillips head screwdriver remove the two power switch mounting screws 11 Replace the case wraparound located directly above and below the 12 Replace the plastic nut from around the power switch pressure regulator Do Not Over tighten 13 Replace the carry handle 9 55 Q a gt g 2 3a PRO CUT 25 LINCOLN 5 F 45 TROUBLESHOOTING amp REPAIR 45 FAN REMOVAL AND REPLACEMENT 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 electrical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC If fo
72. e Represents board soldered to a mother bd Reconnect pilot relay Represents relay soldered to a mother bd 8 vde when open for correct pressure Set air pressure while in purge to 65 psi pressure Switch Closes 43 5 psi Air Guage Supply pressure must be 80 to 150 psi with a flow rate of no less than 4 0 cfm 113 l min 240 cfh LINCOLN 5 Opens 37 7 to 42 psi 2 6 to 2 9 bars Supply for torch amp main air solenoid 12 V regulator CN2 PWM a OVL signal card shunt input 5 4 lt 1 Reed switch BS1 closes when cutting current is drawn file procut25 pp 12 from Control bd 3 11 02 3 6 03 Choke Thermo PCT 3 20 02 WORK CLAMP v BSI AV WRK Cuts for 3 sec then quits stuck in pilot mode or pilot current is 1 2 of CUTTING 12VDC TRANSFER To Control bd 7 1 PILOT Current is 12 amps NZL 2 12V_sw 400Vocv 100 pilot amp cutting 25a 35 duty 115 input 25a 60 duty 230 input 12 to 25 amps range 3 8 max thickness 30 amp input Transfer relay signal from control bd shown in pilot 24 6 8k 5W pip ckt inset detail PC 25 nozzle S22147 028 no drag cups either try without Must be to within 1 8 to transfer to cut SHUNT SH 5
73. e R86 R52 10k PIP DETECT 8V o RESTRIKE nis 21 30 9 A C17 LOW RESTRIKE gt 1 cle R29 R30 R31 515 PREFLDW 5 24 5 5 20 SAFETY LO 47k 270k 10k 6 lt LM324D 10k LOW ERREOR D5044 RSI 7 10 DE Ras RESTRIKE TS TRIG 4 39 gt 8 LM324D CHIGH RESTRIKE TS 2 1 3 D501A 05018 LM324D 10k i 7 10k 18550 PIP DISABLE SAFETY LOCKOUT ARC RESTRIKE RESTRI 15 olo LE R97 R99 8V 4 R9 R71 4 47k 510 10 100k Atv cal olg R96 10u R73 gt a o PREFLOW i 4 OGAS ENABLE say idk ny CHIGH ENABLE 05 2 R70 8 4 9 1 12 5 x 5 TRIG A 8 2 gt LM358D PURGE MS R79 D36 2 U6A R74 150 R9 x 1 3 44 32 48 05 10k 3 7 CF4 1 4 LM324D 470 6 25 SAFETY LO 07 v RESTRIKE TS PREFLOW lt gt 22 49 9 1136 N73 PRESSURE SW 29 GMS DRIVER R84 SAFETY LO 8V R68 029 lt 21 30 5245 00 DETECT 5 95 ae R77 R78 16k 100k 470 470 TS DRIVER 1k 1k 10k PASSE C20 10k D510A R102 5 3 44 47 09 1 GAS ENABLE K TRIG O 4 s pL 45 28 R101 12550 D5108 7 PURGE TS a 4 6 Pa GAS ENABLE amp POSTFLOW TIMER O10 LM358D 47k R81 7 R104 Lincoln Electric Italia s rl
74. e machine is exhibiting Symptoms are grouped into three main categories Output Problems Function 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 conducted without removing the case wrap around cover Step 3 PERFORM COMPONENT TESTS The last column labeled Recommended Course of Action lists the most likely components that may have failed in your machine It also specifies the appropriate test procedure to verify that the subject 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 electrical wiring diagrams and schematics Refer to the Electrical Diagrams Section Table of Contents to locate the appropriate diagram CAUTION If for any reason you do not understand the test procedures or are unable to perf
75. e torch Verify that the air flows for 2 seconds preflow and then the pilot arc is initiated While continuing to hold the trigger verify that the pilot arc remains lit for 3 seconds then turns off automatically Release the trigger and verify that the air continues to flow for 10 seconds postflow Remove the shield cup from the torch and verify that the safety LED turns on Re tighten the shield cup on the torch and verify that the safety LED remains lit Pull the trigger of the torch and verify that a pilot arc does NOT occur Turn the machine off and then back on to clear the safety error Turn the PRO CUT 25 off PRO CUT 25 LINCOLN 5 Return to Master TOC Return to Master TOC o 2 5 Return to Master TOC G 1 G 1 ELECTRICAL DIAGRAMS TABLE OF CONTENTS ELECTRICAL DIAGRAMS SECTION ELECTRICAL DIAGRAMS mmm SECTION G WIRING iio poda Fed cis piso G 2 WIRING DIAGRAM W ADDITIONAL INFO PROCUT 25 G 3 SCHEMATIC CONTROL PRINTED CIRCUIT BOARD SHEET 1 G 4 SCHEMATIC CONTROL PRINTED CIRCUIT BOARD SHEET 2 G 5 SCHEMATIC CONTROL PRINTED CIRCUIT BOARD SHEET G 6 PC BOARD ASSEMBLY MAIN INVERTER G 7 BOARD ASSEMBLY INPUT BOARD G 8 2
76. ection TOC Return to Master TOC Return to Section TOC O10 E 2 212 mlt 5 5 ajo Return to Section TOC Return to Master TOC Return to Master TOC F 21 TROUBLESHOOTING amp REPAIR MAIN INVERTER BOARD VOLTAGE TEST 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 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 troubleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION This test will help determine if the main inverter board is receiving the correct input voltages and if the correct regulated voltages are being processed and maintained by the main inverter board MATERIALS NEEDED Volt Ohmmeter 7mm Nut Driver 4mm Allen Wrench Crescent Wrench PRO CUT 25 LINCOLN 5 F 21 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 Return to Section Return to Master TOC 2
77. er des risques d incendie ou d echauffement des chaines et des cables jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations 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 fortement toxique ou autres produits irritants 11 Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 PR CAUTIONS DE S RET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR 1 Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place LINCOLN 5 iv MASTER TABLE OF CONTENTS FOR ALL SECTIONS RETURN TO MAIN MENU Page
78. es PRO CUT 25 status and operating conditions to the user There are four status indicators Power On Gas Pressure Thermal Overload and Safety Error PRO CUT 25 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC E 2 212 5 Return to Section TOC Return to Master TOC ET THEORY OF OPERATION PROTECTION CIRCUITS Protection circuits are designed into the PRO CUT 25 machine to sense trouble damages problems with internal components and to provide safety These are the main protection circuits OVERLOAD PROTECTION The PRO CUT 25 is electrically protected from producing higher than normal output currents If the output current exceeds 25 30 amps an electronic protection circuit limits the current to within the capabilities of the machine second circuit monitors the input voltage and the voltage across the input filter capacitors If the input voltage or filter capacitor voltage is too high or too low the protection circuit will prevent machine output THERMAL PROTECTION Three thermal protection devices protect the machine from excessive operating temperatures One device is located on the output choke one is located inside the main transformer and another is mounted on one of the IGBT heat sinks Excessive temperatures may be caused by a lack of cooling air or by operating the machine beyond
79. esult in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the LINCOLN ine LINCOLN machine PRO CUT 25 ELECTRICAL DIAGRAMS mo PC 25 TORCH DETAILS AIR FLOW 4 _ des E 75 X helping the push See s AA BRASS CONDUCTOR IR VENT 2 ch 20 WITH A VENT LCA 7 P 4 E VERY LITTLE LA ware COMPRESSED AIR IS FLOWING amp 102 2 de AIR FLOWING ELECTRODE SOL IS at tip Spring is relaxed Return to Section TOC Return to Master TOC 1 No Compressed air flowing Spring is compressed I 2 Air is flowing amp torch solenoid is 6 5 ON 3 _ HOLDS ELECTRODE TO NOZZLE amp s COMPRESSED AIR 4 g 2 f CHAMBERFULLOF EIE COMPRESSED AIR 5 5 Air pressure pushes back DAR SAS electrode creating a LIFT __ start feature inside the nozzle for a pilot arc Tm Flowing pons Solenoid is AS CUTTING CURRENT PATH PILOT amp CUTTING through plasma arc and yellow color parts SUE CURRENT PATH THROUGH TORCH O 515 61 2 2 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 3 PRO CUT 25 SVM ERROR REPORTING FORM We need to know if
80. eturn to Section TOC Return to Master TOC o E st olg 2 212 5 5 Return to Section TOC Return to Master TOC PRO CUT 25 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC E 2 212 mlt 5 5 ajo Return to Section TOC Return to Master TOC Return to Master TOC F 35 TROUBLESHOOTING amp REPAIR INPUT BOARD REMOVAL AND REPLACEMENT 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 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 troubleshooting assistance before you proceed 1 888 935 3877 DESCRIPTION The following procedure will aid the technician in removing the input board for maintenance or replacement MATERIALS NEEDED 4 mm Allen Wrench Crescent Wrench 7 mm Nut Driver Needle Nose Pliers PRO CUT 25 LINCOLN 5 F 35 Return to Section TOC Return to Master TOC Return to Section TOC ojo E gt 212
81. f the cooling air exits in the chamber through vents in the side of the nozzle A swirl texture located inside the bottom of the nozzle increases the plenum air swirl strength and improves arc start reliability and parts in place verification Plasma arc initiation occurs as follows First in the idle state a spring inside the torch head pushes the piston and electrode forward to make continuity with the noz zle When the trigger is pulled air flow begins and cre ates 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 continuity between the consumables After this continuity has been verified output current is estab lished and regulated Once the current 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 orifice of the nozzle This appears as a pilot arc which can then be transferred for cutting Return to Section TOC Return to Master TOC PRO CUT 25 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC ojo O gt 212 ele 5 5 ajo Return to Section TOC Return to Master TOC
82. for 5 minutes to let the input capacitors discharge 3 Remove the machine cover 4 Replace the blown fuse with a new 0 5A 500V slowblow fuse or 32A 400V fuse as appropriate NOTE If the fuse blows again after power is restored the cause could be an internal breakdown in the power unit In this case take the unit to an authorized Lincoln Field Service Shop PRO CUT 25 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O o 515 gt 2 2 2 EE Return to Section TOC Return to Master TOC D 3 N O O1 B ND Central Metal Wall Main Board Input Board Control Board Fan Case Wraparound Torch MAINTENANCE FIGURE 0 2 MAJOR COMPONENT LOCATIONS PRO CUT 25 LINCOLN 5 D 4 NOTES LINCOLN 5 O N gt o oc 901 Je1Se A 901 Je1Se A 0 901 J91Se N 01 901 J91Se N 0 DOL DOL uonoes uumeg DOL DOL Section E 1 Section E 1 TABLE OF CONTENTS P THEORY OF OPERATION SECTION 5 Theory Section 9 General DESCHIPTION dina E 2 Input Line Voltage and Auxiliary E 2 Prechargesand
83. form the Torch Continuity and Solenoid Test Perform the Main Inverter Board Voltage and Resistance Tests The control board may be faulty Replace The machine powers up properly and cuts OK with 230 input applied With 115 applied the pilot arc ignites but goes out when cut ting commences Or no pilot or cutting when 115 input is supplied CP leads to its terminal from the input to the inverter board are loose or disconnected Reconnect the leads to its cor rect terminal per the wiring dia gram Perform the Input Board Test The input board may be faulty Replace The air begins to flow when the torch trigger is pulled There is a very brief pilot arc Normal is 3 Seconds The sequence is repeat ed with subsequent trigger pulls Check the input voltage at the machine Input voltage must match the rating plate Make sure the torch consumable parts are in place and in good condition Replace if necessary Make sure there are no kinks or restrictions for air flow in the torch cable Make sure the air pressure is Set at 65psi Make sure that the correct size nozzle is being used Must be a 028 orifice Pro Cut 55 size nozzles will not work with the PC 25 system PRO CUT 25 LINCOLN 5 Check all connectors and wires for loose or faulty connections See Wiring Diagram Perform the Board Voltage and Resistance Tests The control board may be faulty Replace
84. former is made up of one winding This winding supplies the electrode to nozzle and electrode to work voltages and the resulting currents This high current winding is capable of supplying maximum output current during the cutting process The output current is regulated via pulse width modulation The control circuitry on the inverter board receives a signal from the control board and regulates the output current to the desired level Return to Section TOC Return to Master TOC PRO CUT 25 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O o Fle S PEN 2 8 mlt 5 2 Im E 5 WORK CLAMP NZL 2 FIGURE E 5 PLASMA OUTPUT SECTION AND TORCH L1 RL3 RL l LB 30000 M 55 B zH 1 Input R24 6 8k 5W Q2a b c IRG4BC30W SHUNT JEL 3 OL gH SH 12 Solenoid 2 Main Inverter Board Voltage Board 16121 8141 114 137 192421238 14 1 3 9 MS 20 01 MS A8 019 235 CN EEE 933 1 3399191 114100 110 A 8 105 Lu QV01A0 MS H3dSNVUl 105
85. free methods for handling printed circuit boards Failure to do so can result in per manent damage to the equipment 10 Using a 7mm nut driver remove the three screws that hold the case front to the central metal wall This will allow the case front to be gently pulled forward so the Control board can be removed See Figure F 15 Remove the Four allen bolts with a 2 5 mm allen wrench 11 12 14 15 Carefully remove the plug and lead assembly from the control board At this point the control board is ready for removal GENTLY pull the case front forward and carefully remove the Control board Replace the Control Board by GENTLY pulling the case front forward and carefully sliding the Control board back into its original position Reconnect plug and lead assembly Replace the four allen mounting screws Replace the screws connecting the case front to the central metal wall PRO CUT 25 LINCOLN 5 TROUBLESHOOTING amp REPAIR CONTROL BOARD REMOVAL AND REPLACEMENT continued olo O O 16 Replace the red PURGE button 5 9 d 17 Replace the plastic OUTPUT knob 2 align it in its original position 5 tighten nut 5 5 18 Replace the red on the end of cc the OUTPUT knob 19 Replace the case wraparound 20 Replace the plastic nut from around the pressure regulator Do Not Over tighten 21 Replace the carry handle R
86. hield cup does not prevent the torch tip from touching the workpiece K1615 Series PCT 20 Torches come in 15 and 25 lengths Refer to the Parts Pages in the rear of this manual for Torch parts PRO CUT 25 LINCOLN 5 Section D 1 Section D 1 TABLE OF CONTENTS MAINTENANCE Maintenance Section D Ro tirie Mainterlarice ccce ee EE ce D 2 Periodic Maltiteriance iet ee dide Leste ed Ee D 2 Thermal Protecti cii ooi torret iore ooi coca ev eae nee tonnes D 2 Return to Master TOC Replacement Of Internal D 2 Major Component Locations o rrr e D 3 Return to Master TOC Q 2 5 Return to Master TOC PRO CUT 25 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC E olg 2 212 5 5 Return to Section TOC Return to Master TOC Return to Master TOC nin MAINTENANCE A WARNING ELECTRIC SHOCK can kill Have an electrician install and service this equipment Turn the input power off at the fuse box befo
87. hly 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 plasma cutting or gouging on galvanized steel 3 5 The operation of plasma cutting or gouging fume control equipment is affected by various factors including proper use and positioning of the equipment maintenance of the equip ment and the specific procedure and applicaiton involved Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH limits 3 c Do not use plasma cutting or gouging equipment in locations near chlorinated hydrocarbon vapors coming from degreas ing 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 Gases used for plasma cutting and gouging 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 follow your employer s safety practices _g CUTTING SPARKS cause fire or explosion 4 a Remove fire hazards from the plasma cutting or gouging area If this is not possible cover
88. ine filter is recom mended however for optimum performance select a prefilter with a 3 micron absolute rating If these filter ratings are unavailable anything with a rating less than or equal to 20 micron would be acceptable to use In line filter elements will generally filter the air with little restriction to the airflow until the element is about 75 contaminated After this point there will be a noticeable pressure drop in the line Filter ele ments should be replaced when a pressure drop of 8 10 psi is indicated however for optimum perfor mance of the PRO CUT 25 the filter element should be replaced at or before the pressure drop reaches 8 psi Be sure to select a filter that will accommodate the necessary flow rating for the PRO CUT 25 as specified in the Installation section of this instruction manual under the Gas Input Connections heading PRO CUT 25 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 Return to Section Return to Master TOC Q 2 5 5 INSTALLATION NOTE When using nitrogen gas from a cylinder the cylinder must have a pressure regulator Maximum psi from a nitrogen gas cylinder to the PRO CUT 25 regulator should never exceed 150 psi Install a hose between the nitrogen gas cylinder regulator and the PRO CUT 2
89. ions PILOT ARC DISCUSSION The PRO CUT has a smooth continuous pilot arc The pilot arc is only a means of transferring the arc to the workpiece for cutting Repeated pilot arc starts in rapid succession is not recommended as these starts will generally reduce consumable life Occasionally the pilot arc may sputter or start intermittently This is aggravated when the consumables are worn or the air pressure is too high Always keep in mind that the pilot arc is designed to transfer the arc to the 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 PRO CUT 25 LINCOLN 5 id OPERATION PROCEDURE RECOMMENDATIONS When properly used plasma arc cutting is a very eco nomical process Improper use will result in a very high operating cost 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 nozzle and electrode and use the electrode to rub against General In All Cases the inside bottom surface of the nozzle This will Return to Section TOC Return to Master TOC Return to Section TOC
90. l plasma cutting applications Based on U S National Electrical Code Ambient Temperature 30 C or Less Output AC Input Input Cord Fuse Type 75 C Voltage Plug Super Lag Copper Wire in Conduit at Size Circuit Breaker AWG IEC Sizes 50 60 Delay Type Hertz 2 Input Supply Wires 1 Ground Wire 230V 10 6 20P or 6 30P or 6 50P 20 AMPS 14 2 5 14 2 5 115V 1 5 15P or 5 20P or 5 30P 5 50P 15 AMPS 12 4 mm 12 4 mm 115 10 5 20P or 5 30P or 5 50P 20 AMPS 12 4 mm 12 4 mm 115 10 5 5 30 5 12 4 mm 12 4 mm PHYSICAL DIMENSIONS Weight Including Torch Cable 35 lbs 15 9 kg Included with machine PRO CUT 25 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 Return to Section TOC Return to Master TOC 2 5 ii INSTALLATION aT Read entire Installation Section before installing the PRO CUT 25 SAFETY PRECAUTIONS A WARNING ELECTRIC SHOCK CAN KILL Only qualified personnel should install this machine Turn the input power OFF at the disconnect switch or fuse box and discharge input capacitors before working inside the equipment Do not touch electrically hot parts Turn the PRO CUT Power Switch OFF when connecting power cord to input power SE
91. lso monitors the filter capacitors the inverter board The resultant DC voltage is applied for overvoltage If this occurs the appropriate signal to the filter capacitors through the automatic is sent to the control board to disable the machines reconnect of the input board The input board also output and to turn on the Thermal Voltage Overload contains precharging circuitry for the safe charging of status LED See IGBT Operation discussion the input filter capacitors Once the capacitors are diagrams in this section precharged the input board activates the input relay This connects full input power to the filter capacitors When the filter capacitors are fully charged they act as power supplies for the IGBT switching circuit The IGBTs supply the main trans former primary winding with DC current flow NOTE Unshaded areas of Block Logic Diagram are the subject of discussion PRO CUT 25 LINCOLN 5 ET THEORY OF OPERATION zi FIGURE E 4 TRANSFORMER 2 TTE WORK CLAMP o 3 IRG4BC30W 010 wrk S Biz 8 pril 12 25 2 2 ca 011 NZL 2 AC Rolle
92. n ditions OPERATIONAL FEATURES AND CONTROLS The PRO CUT 25 comes with an ON OFF POWER SWITCH OUTPUT CURRENT CONTROL and PURGE BUTTON DESIGN FEATURES AND ADVANTAGES The PRO CUT 25 design makes plasma cutting uncomplicated This list of design features and advan tages will help you understand the machine s total capabilities so that you can get maximum use from your machine Light weight and portable design for industrial use Continuous control 12 25 amps Reliable touch start mechanism for plasma arc initia tion Rapid arc restrike for fast cutting of expanded metal Input over voltage protection Bright 3 0 second timed pilot arc Purge momentary push button Air regulator and pressure gage included Parts in Place mechanism to detect proper installa tion of consumables and torch Latching Parts in Place mechanism Requires the operator to turn the machine off and then on to reset Preflow Postflow timing Preflow is eliminated if arc is re initiated in Postflow Thermostatic Protection Solid state over current protection Automatic reconnect for 115 VAC or 230 VAC inputs Dead front display 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 PRO CUT 25 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Ret
93. n 1 8 1 4 from the work piece the arc will transfer the current POWER GAS PRESS saer 1 A 465 Return to Master TOC o 2 5 2 3 2 When preparing to cut position the machine as close will ramp to the setting on the control panel and to the work as possible Make sure you have all mate the cut can last indefinitely or until the duty o lo rials needed to complete the job and have taken all cycle of the Pro Cut is exceeded safety precautions It is important to follow these oper ating steps each time you use the machine Pierce the work piece by slowly lowering the torch B 8 onto the metal at a 30 angle away from the operator Turn the machine s ON OFF POWER SWITCH to This will blow the dross away from the torch tip 4 OFF position Slowly rotate the torch to vertical position as the arc becomes deeper 5 Connect the air supply to the machine a TORCH 30 ANGLE Turn the main power and the machine power switch TOPIERGE on The fan should start The pre charge circuit will operate for 3 seconds ROTATE TO then the green Power LED should turn on 90 ANGLE TO CUT Be sure that the work lead is clamped to the work piece before cutting olo S FOR CUTTING 66 Set the output current control knob at maximum position for higher cutting speed and less dross for
94. ncoln 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 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 troubleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION The following procedure will aid the technician in removing the SWITCH for maintenance or replacement MATERIALS NEEDED 4 mm Allen Wrench Crescent Wrench 7 mm Nut Driver Phillips Head Screwdriver Flat Head Screwdriver PRO CUT 25 LINCOLN 5 F 43 o 9 2 E 2 44 TROUBLESHOOTING amp REPAIR SWITCH REMOVAL AND REPLACEMENT continued FIGURE F 20 SWITCH Switch Ru F 44 e 5 5 0 olg a gt 2 9 513 Pc PROCEDURE i Remove input power to PRO CUT 25 T Carefully remove the power switch assembly from the front of the machine 2 Remove carrying handle using a making note of insulation positioning 4mm allen wrench 8 Carefully label and identify the four leads and their terminals before removing e 9 3 Using a
95. ng arc weld ing operations and any other source of heat sparks or flame Never allow any part of the electrode torch or any other elec trically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve 5 f Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use 5 g Read and follow the instructions on compressed gas cylin ders associated equipment and CGA publication 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 6 a Turn off input power using the disconnect switch at the fuse box before working on the equipment 6 b Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s rec ommendations 6 c Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations PLASMA ARC can injure 7 a Keep your body away from nozzle and plasma arc 7 b Operate the pilot arc with caution The pilot arc is capable of burning the operator others or even piercing safety clothing ELECTRIC AND MAGNETIC FIELDS may be dangerous 8 a Electric current flowing through any conduc tor causes localized Electric and Magnetic Fields
96. ng 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 after normal One of the machine s thermal Check all connectors and wires use protection circuits has tripped for loose or faulty connections Do not turn the PRO CUT 25 off See Wiring Diagram Allow the machine to cool The thermal protection circuits will reset themselves The inverter board may be faulty Replace The control board may be faulty Either the duty cycle has been Replace exceeded the fan is not func tioning or the louvers are Use the correct extension cord blocked See the instruction manual Thermo light comes on when over voltage occurs 10 must be with in 10 Return to Section TOC Return to Master TOC ojo O10 E 2 gt 212 5 5 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 1 888 935 3877 Return to Section TOC Return to Master TOC PRO CUT 25 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC E gt 212 5 5 ojo Return to Section TOC Return to
97. o 9 the gas pressure Pull the pressure regulator cap out Do not exceed output current and duty cycle rating of turn Eto set ihe pressure 519 machine Do not use the PRO CUT 25 for pipe thaw cum gas regulator Tor Go 16 Br 25 3 o2 ing Release the Purge button ain 2 The gas will immediately turn off The pressure E 3 CONTROLS AND SETTINGS gage may show an increase in pressure after the 2 PRESSURE REGULATOR air turns off but this is normal Do NOT reset the pressure 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 Exceptions the first time that the trigger is pulled after the machine is turned on or after a thermal tripout will be ignored This is a safety feature to prevent the PRO CUT 25 pilot arc from firing unexpectedly or if the torch button is pressed because it is laying up against something The other exception is if 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 0 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 When the arc is brought withi
98. o try and cut with excessively worn consumables as this can cause damage to the torch head and will degrade cut quality Do not allow torch cable or body to contact hot surface To improve consumable life here are some sug gestions that may be useful a Make sure the air supply to the Pro Cut is clean and free of oil Use several extra in line filters if necessary b Minimize dross buildup on the nozzle tip by starting the cut from the edge of the plate when possible c Pierce cutting should be done only when nec essary If piercing angle torch about 30 from the plane perpendicular to the work piece transfer the arc then bring the torch perpen dicular to the work and begin parallel move ment d Reduce the number of pilot arc starts without transferring to the work e Reduce the pilot arc time before transferring to the work f 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 g Use only Lincoln consumable parts These parts are patented and using any other replacement consumables may cause damage to the torch or reduce cut quality PRO CUT 25 LINCOLN 5 B 8 NOTES LINCOLN 5 O N gt o oc 901 Je1Se A 901 Je1Se A 0 901 J91Se N 01 901 J91Se N 0 DOL DOL uonoes uumeg DOL DOL
99. ody protection can injure Keep your body away from nozzle and plasma arc Operate the pilot arc with caution The pilot arc is capable of burning the operator others or even piercing safety clothing PLASMA ARC Observe additional Safety Guidelines detailed the beginning of this manual B DESCRIPTION The PRO CUT 25 is a constant current continuous control plasma cutting power source It provides supe rior and reliable starting characteristics cutting visibili ty and arc stability The control system has a safety mechanism to insure that the nozzle and electrode are in place before cutting or gouging This is extremely important due to the high voltages involved The PRO CUT 25 comes standard with an air regula tor and pressure gauge The machine also comes with an input power cord Hand held torches are available in 15 or 25 cable Consumables are included with each Pro Cut purchase so that cutting can begin right out of the box Consumables can also be ordered as individual packages The PRO CUT 25 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 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 ca
100. or gouging They may explode 4 f Do nor fuel engine driven equipment near area where plasma cutting or gouging 4 g Sparks and spatter are thrown from the plasma arc Wear safe ty glasses ear protection and oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when cutting or goug ing out of position or in confined places Always wear safety glasses with side shields when in a cutting or gouging area 4 h Connect the work cable to the work as close to the cutting or gouging area as practical Work cables connected to the build ing framework or other locations away from the cutting or goug ing area increase the possibility of the 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 CYLINDER may explode if damaged 5 a Use only compressed gas cylinders contain ing the correct gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition 5 b Always keep cylinders in an upright position securely chained to an undercarriage or fixed support 5 c Oylinders should be located Away from areas where they may be struck or subjected to physical damage A safe distance from plasma cutting or gougi
101. orm the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 PRO CUT 25 LINCOLN 5 F 2 Return to Section TOC Return to Master TOC Return to Section TOC 2 212 5 Return to Master TOC TROUBLESHOOTING amp REPAIR BOARD TROUBLESHOOTING PROCEDURES ELECTRIC SHOCK can kill Have an electrician install and service this equipment Turn the machine OFF before working on equipment Do not touch electrically hot parts Sometimes machine failures appear to be due to PC board failures These problems can sometimes be traced to poor electrical connections To avoid prob lems when troubleshooting and replacing PC boards please use the following procedure 1 Determine to the best of your technical ability that the PC board is the most likely component caus ing the failure symptom 2 Check for loose connections at the PC board to assure that the PC board is properly connected 3 If the problem persists replace the suspect PC board using standard practices to avoid static electrical damage and electrical shock Read the warning inside the static resistant bag and perform the following procedures PC Board can be damaged by static electricity Remove your body s static charge before opening the static shielding bag Wear an an
102. orts Check each IGBT 6 from Gate to Collector Normal resistance is approx imately 100 ohms Return to Section TOC Return to Master TOC Also check each device from Gate to Emitter Normal resistance is approximately 40 ohms Check each device from Emitter to Collector Normal reading is high resistance in one polarity and a low resistance in the opposite polarity Note These devices will usually fail short resulting in a zero or very low resistance reading If they open physical damage should be evident FIGURE F 3 LOCATION OF IGBTs 6 Return to Section TOC Return to Master TOC LEAD 2 NZL WRK LEAD 3 EL Plug J1 Harness O 2 c 2 Plug o 2 5 2 RIGHT SIDE OF MACHINE GCE Return to Section TOC Return to Master TOC PRO CUT 25 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC ojo E gt 212 5 5 Return to Section Return to Master TOC TROUBLESHOOTING amp REPAIR diii MAIN INVERTER BOARD RESISTANCE TEST continued 9 Check Diodes D1 D2 amp D3 for shorts or opens Keep in mind that unless these devices are electrically isolated from the circuit some resistance will be read in both polarities See the Wiring Diagram Figure F 4
103. r Board Removal and F 39 Switch Removal and Replacement F 43 Fan Removal and Replacement iii F 45 F 48 5 o 8 2 5 D 2 5 c PRO CUT 25 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC ojo O10 E gt 212 5 5 ajo Return to Section TOC Return to Master TOC Return to Master TOC F 2 TROUBLESHOOTING amp REPAIR HOW TO USE TROUBLESHOOTING GUIDE CAUTION 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 malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMPTOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that th
104. r Transistors IGBT s Also it will indicate if P1 is shorted or open MATERIALS NEEDED Analog Volt Ohmmeter Wiring Diagram 7mm Nut Driver 4mm Allen Wrench Crescent Wrench PRO CUT 25 LINCOLN 5 F 11 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 Return to Section Return to Master TOC o 2 5 di TROUBLESHOOTING amp REPAIR dis MAIN INVERTER BOARD RESISTANCE TEST continued FIGURE F 2 LEAD 2 NZL WRK LEAD 3 EL Plug J1 Harness Plug RIGHT SIDE OF MACHINE TEST PROCEDURE 1 Remove main input power to the PRO CUT 5 Perform the Input Filter Capacitor Discharge 25 Procedure detailed earlier in this section 2 Remove carrying handle using a 4mm 6 Visually check for burned or damaged compo nents If any components are physically dam 3 Using a crescent wrench carefully remove the aged or determined to be faulty the Main plastic nut from around the pressure Inverter Board should be replaced regulator located on the top of the machine 7 Check the input rectifier bridge 1 for 4 Using a 7mm nut driver remove the case shorts or opens See Figure F 2 wraparound PRO CUT 25 LINCOLN 5 TROUBLESHOOTING 8 REPAIR MAIN INVERTER BOARD RESISTANCE TEST continued 8 Check the IGBTs for sh
105. r 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 1 888 935 3877 DESCRIPTION The following procedure will aid the technician in removing the fan for maintenance or replacement MATERIALS NEEDED Return to Section TOC Return to Master TOC 4mm Allen Wrench Crescent Wrench 7mm Nut Driver Phillips Head Screwdriver O10 E 2 212 mlt 5 5 ajo Return to Section TOC Return to Master TOC PRO CUT 25 LINCOLN 5 F 46 TROUBLESHOOTING amp REPAIR pae o 8 FAN REMOVAL AND REPLACEMENT continued 5 5 zly PROCEDURE 2 1 Remove input power to PRO CUT 25 4 Using a 7mm nut driver remove 912 the case wraparound 2 Remove carrying handle using 4mm allen wrench 5 Perform 3 Using a crescent wrench carefully remove the plastic nut from around the 6 Label and remove the two leads pressure regulator located on the top of connected to the top of the fan Be the machine sure to correctly label these leads and note their positions FIGURE F 21 FAN LOCATION Return to Section TOC Return to Master TOC O o 515 gt 2 2 2 EE Return to Section TOC Return to Master TOC PRO CUT 2
106. rbon alloy steels and heat treated aluminum for crack resistance and hardness control Job conditions pre vailing codes alloy level and other considerations may also require preheat temperature control The following minimum preheat temperature is recommended as a starting point Higher temperatures may be used as required by the job conditions and or prevailing codes If cracking or excessive hardness occurs on the cut face higher preheat temperature may be required The rec ommended minimum preheat temperature for plate thickness up to 1 2 12 7mm is 70 F 21 190 PRO CUT 25 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 Return to Section Return to Master TOC 2 5 OPERATION USER RESPONSIBILITY Because design fabrication erection and cutting vari ables affect the results obtained in applying this type of information 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 flowrate and equipment may produce results different than those expected Some adjustments to procedures may be necessary to compensate for unique individual con ditions Test all procedures duplicating actual field co
107. re working on equipment Do not touch electrically hot parts Prior to Performing preventative main tenance perform the following capaci tor discharge procedure to avoid elec tric shock 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 2 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 Printed circuit boards and heat sinks Power switch A CAUTION When using a low pressure aistream wear appropiate eye protection 3 Examine the sheet metal case for dents or break age Repair the case as required Keep the case in good condition to insure that high voltage parts are protected and correct spacings are maintained All external sheet metal screws must be in place to insure case strength and electrical ground continu ity 4 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 peri odically and relieve any so as not to restrict the flow of air to the torch PERIODIC MAINTENANCE A WARNING ELECTRIC SH
108. rn to Section TOC Return to Master TOC 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 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 troubleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION This test will help determine if the correct input voltage is being applied to the input board and will also determine if the correct voltages are being processed and regulated on the input board Return to Section TOC Return to Master TOC MATERIALS NEEDED Volt Ohmmeter 7mm Nut Driver 4mm Allen Wrench Crescent Wrench E 2 212 mlt 5 5 ajo Return to Section TOC Return to Master TOC PRO CUT 25 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 Return to Section Return to Master TOC 2 5 F 18 1 Using crescent wrench TROUBLESH
109. ted tightly to the work piece The work piece must be electri cally conductive material and the work clamp must make a good electrical connection with the work piece Do not use a drag cup Not recommended for Pro Cut 25 use Perform The control Check all connectors and wires for loose or faulty con nections See Wiring Diagram the Board Voltage and board may be faulty Replace Trigger or purge is activated brief air flow then the safety light illumi nates The Control Board is defective Replace Poor performance of pilot arc or cutting Poor consumable life Check pressure switch to be functioning correctly opening closing at its correct pressure Check pressure gauge to be correct in its reading Check for recommended flow rate coming from the torch end with a flow meter PRO CUT 25 LINCOLN 5 Try increasing or decreasing the air pressure to see if conditions improve Replace regulator or pressure switch may be required Screen in air line at inlet to air solenoid may be clogged Clean no screen before 7 1 02 Ensure that air is clean and dry External filters may be used Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 Return to Section TOC Return to Master TOC 2 5
110. the discharge procedure for the other capacitors 10 Check the voltage across the terminals of all capacitors with a DC voltmeter Voltage should be zero If any voltage remains repeat this capacitor discharge procedure FIGURE F 1 LOCATION OF INPUT FILTER CAPACITOR TERMINALS INSULATED PLIERS CAPACITOR TERMINALS RIGHT SIDE OF MACHINE INSULATED GLOVES POWER RESISTOR PRO CUT 25 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC ojo O10 E gt 212 mlt 5 5 ajo Return to Section TOC Return to Master TOC Return to Master TOC F 11 TROUBLESHOOTING amp REPAIR MAIN INVERTER BOARD RESISTANCE TEST 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 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 troubleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION This test will determine if the main inverter board has any shorted or leaky power diodes or Insulated Gate Bipola
111. them to prevent the cutting or gouging sparks from starting a fire Remember that welding sparks and hot materials from plasma cutting or gouging can easily go through small cracks and openings to adjacent areas Avoid cutting or gouging near hydraulic lines Have a fire extinguisher readily available 4 b Where compressed gases are to be used at the job site spe cial precautions should be used to prevent hazardous situa tions Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used Aug 06 LINCOLN 5 Return to Master TOC Return to Master TOC 2 5 Return to Master TOC SAFETY i 4 c When not cutting or gouging make certain no part of the elec trode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard 4 d Do not cut or gouge tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above 4 e Vent hollow castings or containers before heating cutting
112. there are errors in our manuals We also value any suggestions as to additional tests or procedures that would make this SVM a better tool for you Return to Master TOC If you discover new or different Problems or Symptoms that not covered in the three col umn troubleshooting chart please share this information with us Please include the machine s code number and how the problem was resolved Thank You Technical Services Group Lincoln Electric Co 22801 St Clair Ave Cleveland Ohio 44117 1199 FAX 216 481 2309 Return to Master TOC SVM Number Page Number if necessary Your Company Your Name Please give detailed description below Q 2 2 c 5 50287 04 06 Return to Master TOC
113. ti sta tic wrist strap For safety use a Aa ATTENTION Static Sensitive 1 Meg ohm resistive cord con Devices nected to a grounded part of the Handle only at equipment 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 prevent static build up Be sure not to touch any electrically live parts at the same time Workstations Reusable Container Do Not Destroy Tools which come in contact with the PC Board must be either conductive anti static or static dissipative e Remove the PC Board from the static shielding bag and place it directly into the equipment Don t set the PC Board on or near paper plastic or cloth which could have a static charge If the PC Board can t be installed immediately put it back in the static shielding bag f the PC Board uses protective shorting jumpers don t remove them until installation is complete f you return a PC Board to The Lincoln Electric Company for credit it must be in the static shielding bag This will prevent further damage and allow proper failure analysis 4 Test the machine to determine if the failure symp tom has been corrected by the replacement PC board NOTE Allow the machine to heat up so that all electrical components reach their operating temperature 5 Remove the replacement PC board and substitute it with the original PC bo
114. turn to Master TOC o 2 tc Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC G 3 WIRING DIAGRAM W ADDITIONAL INFO Typical input current draw 115v 25 35 37 74 20A 60 26 74 230 25 60 19A 20A 100 15A 12 vdc Listen for relay to click in after a 3 sec delay Auto Reconnect Feature Soft start relay 3 to 5 sec delay ELECTRICAL DIAGRAMS All thermo devices are on this inverter board PRO CUT 25 63 khz 100khz 25 PC20 operating freq Soft start resistor over heats 208 input Q1a RL3 IRG b c 4BC30W Shown in 230 lt 1500uF 250V de energized C26 7 Main gt Caps PT2 does it work 2 11 E AC AC NC in the other input 2 gt A B 4 voltage 115v or 230 v 300uH RE CP us A input bd lt lt 230vac when in 230 Must be within 1 10 of input V Must be greater than 208v RS 02 8 is 15 the voltage reconnect for 110V RG4 BC30W YES for Ranger 250 series operibon es Commander 300 400 500 s Me 420 Vdc for NO parts in place pip driver C 1 3 50hz 60 hz 6 Vde with parts IN card RPM s 2700 3100 vac 4 amps 13 12 runs all the tim
115. urn to Master TOC o 2 5 2 Return to Section Return to Master TOC Q 2 5 ke CUTTING CAPABILITY The PRO CUT 25 is rated at 25 amps at 35 duty cycle on a 10 minute basis If the duty cycle is exceeded a thermal protector will shut off the output of the machine until it cools to the normal operating temperature Figure B 1 shows the cut capacity of the PRO CUT 25 when cutting mild steel The graph plots cut thickness vs torch travel speed with a torch standoff of 0 15 Lincoln s PRO CUT 25 Cut Capacity Chart 80 go 24 8 60 2 40 meo 20 0 0 125 0 250 0 375 Metal Thickness Inches Figure B 1 CONSUMABLE LIFE The expected life for the PRO CUT 25 s electrode under normal operating conditions is approximately 1000 starts cuts An erosion of 060 is typical for end of electrode life however the electrode life may last longer A green and erratic arc will indicate definite electrode failure and the electrode should be replaced immediately It is recommended that consumables be replaced in complete sets Example Electrode and Nozzle This will maximize the performance of the PRO CUT 25 system PRO CUT 25 LINCOLN 5 BS OPERATION ES LIMITATIONS Push in and hold the Purge button to check or set

Lincoln Electric SVM149

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