Lincoln Electric FlexCut 200 Service Manual
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Lincoln Electric FlexCut 200 Service Manual

Lincoln Electric FlexCut 200 Service Manual

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FlexCut ® 200
For use with machines having Code Numbers:
FlexCut ® 200: 12731
SERVICE MANUAL
SVM288
| Issue D ate 18-Aug
© Lincoln Global, Inc. All Rights Reserved.

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  • Page 1 FlexCut ® 200 For use with machines having Code Numbers: FlexCut ® 200: 12731 SERVICE MANUAL SVM288 | Issue D ate 18-Aug © Lincoln Global, Inc. All Rights Reserved.
  • Page 2 THANK YOU FOR SELECTING A QUALITY PRODUCT BY KEEP YOUR HEAD OUT OF THE FUMES. DON’T get too close to the arc. LINCOLN ELEC TRIC. Use corrective lenses if necessary to stay a reasonable distance away from the arc. READ and obey the Safety Data PLEASE EXAMINE CARTON AND EQUIPMENT FOR Sheet (SDS) and the warning label DAMAGE IMMEDIATELY...
  • Page 3 MAGNETIC FIELDS MAY W117.2-1974. A Free copy of “Arc Welding Safety” booklet BE DANGEROUS E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. 2.a. Electric current flowing through any conductor BE SURE THAT ALL INSTALLATION, OPERATION, causes localized Electric and Magnetic Fields (EMF).
  • Page 4 S FETY ELECTRIC SHOCK ARC RAYS CAN BURN. CAN KILL. 3.a. The electrode and work (or ground) circuits are 4.a. Use a shield with the proper filter and cover plates to protect your electrically “hot” when the welder is on. Do eyes from sparks and the rays of the arc when welding or not touch these “hot”...
  • Page 5 S FETY WELDING AND CUTTING CYLINDER MAY EXPLODE IF SPARKS CAN CAUSE DAMAGED. FIRE OR EXPLOSION. 7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used 6.a. Remove fire hazards from the welding area. If and properly operating regulators designed for this is not possible, cover them to prevent the welding sparks the gas and pressure used.

  • Page 6: Table Of Contents

    LINCOLN ELECTRIC FlexCut® 200 Service Manual FlexCut® 200 Service Manual Last update: 2018/08/01 FLEXCUT® 200 ............................1 Service Manual................................1 Block Diagram................................3 Troubleshooting & Repair ............................5 HOW TO USE TROUBLESHOOTING GUIDE ....................5 PC BOARD TROUBLESHOOTING PROCEDURES ..................6 Troubleshooting guide .............................
  • Page 7 LINCOLN ELECTRIC FlexCut® 200 Service Manual PILOT BOARD TEST PROCEDURE ......................59 MAIN CURRENT LEM TEST PROCEDURE ....................63 PILOT CURRENT LEM TEST PROCEDURE ....................66 ARCLINK I/O BOARD TEST PROCEDURE ....................69 PRESSURE SENSE BOARD TEST PROCEDURE ................... 73 40 VDC BUS BOARD TEST PROCEDURE ....................

  • Page 8: Block Diagram

    FlexCut 200 USER PILOT ARCLINK ARCLINK ARCLINK TO SWITCH WORK INTERFACE CURRENT CONNECTION CONNECTION I/O BOARD BOARD STUD BOARD MAIN THREE PHASE INPUT INPUT SWITCH MAIN SNUBBER OUTPUT ELECTRODE CURRENT INPUT POWER SWITCH RECTIFIER BOARD TRANSFORMER BOARD CHOKE STUD FROM SWITCH...
  • Page 9 FlexCut 200 USER INTERFACE BOARD 10. SWITCH BOARD 18. SOLENOIDS 26. VOLTAGE DIVIDER BOARD Allows the user to select Converts rectified 50/60 Hz There are three solenoids, one Provides non-isolated modes, adjust work point and input to high frequency output to energize the cutting gas, feedback of voltage potential display pressure via a digital of 20 kHz.

  • Page 10: Troubleshooting & Repair

    Troubleshooting & Repair HOW TO USE TROUBLESHOOTING GUIDE 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.

  • Page 11: Pc Board Troubleshooting Procedures

    ELECTRIC SHOCK can kill. remove them until installation is complete. • If you return a PC board to The Lincoln Electric Company • Have an electrician install and service this for credit, it must be in the static-shielding bag. This will equipment.

  • Page 12: Troubleshooting Guide

    2. Perform the ArcLink I/O Board Test Procedure. Board. 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.
  • Page 13 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.
  • Page 14 6. Perform the Pilot Board Test Procedure. 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.

  • Page 15: Error Codes

    LINCOLN ELECTRIC FlexCut® 200 Service Manual Error Codes Observe Safety Guidelines ERROR CODES detailed in the beginning of this manual. ERROR CODE POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION Communication error between Cycle power to the machine to power board and control see if error clears.
  • Page 16 LINCOLN ELECTRIC FlexCut® 200 Service Manual Peak current through the Verify connections to the transformer primary has switch board, transformer and exceeded threshold (140 output rectifier assemblies are amps). made correctly and there are no damaged components in the machine.
  • Page 17 LINCOLN ELECTRIC FlexCut® 200 Service Manual The water cooler object was Connect a water cooler that not found and is required in the has a control board (FlexCool system. 35). If not using a water cooler, reset the 'Fault if No Cooler' attribute using Power Wave Manager Misc tab.
  • Page 18 LINCOLN ELECTRIC FlexCut® 200 Service Manual Trigger locked. Release the trigger before continuing. The trigger must be disabled at machine startup or when changing modes. The door to the Flexstart Close the Flexstart door and console is open. latch it tightly.
  • Page 19 LINCOLN ELECTRIC FlexCut® 200 Service Manual Thermistor missing. NTC thermistor is not plugged in, ambient temperature is too low or thermistor is damaged.

  • Page 20: Test Procedures

    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.
  • Page 21 LINCOLN ELECTRIC FlexCut® 200 Service Manual Figure F.1 – Eye bolt and roof mounting screw locations Figure F.2 – Side panel mounting screw locations...

  • Page 22: Capacitor Discharge Procedure

    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.
  • Page 23 LINCOLN ELECTRIC FlexCut® 200 Service Manual Figure F.3 – Switch board terminal 207 and 209 locations Figure F.4 – Capacitor (C1) location...
  • Page 24 LINCOLN ELECTRIC FlexCut® 200 Service Manual Figure F.5 – Capacitor terminal locations...

  • Page 25: Input Rectifier (D1) Test Procedure

    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.
  • Page 26 LINCOLN ELECTRIC FlexCut® 200 Service Manual Figure F.6 – Input rectifier (D1) location Figure F.7 – Input rectifier (D1) detail...

  • Page 27: Auxiliary Transformer (T2) Test Procedure

    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.
  • Page 28 LINCOLN ELECTRIC FlexCut® 200 Service Manual Table F.2 – Primary and secondary voltage tests DESCRIPTION TEST POINT TEST POINT EXPECTED READING PRIMARY VOLTAGE 380 VAC (460 VAC H1 to H3) PRIMARY VOLTAGE 460 VAC (460 VAC H1 to H3) PRIMARY VOLTAGE...
  • Page 29 LINCOLN ELECTRIC FlexCut® 200 Service Manual Figure F.9 – Auxiliary rectifier (D4) lead locations Figure F.10 – 115V receptacle location...

  • Page 30: Fan And F.a.n. Circuit Test Procedure

    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.
  • Page 31 LINCOLN ELECTRIC FlexCut® 200 Service Manual If no error 36 flashes and the thermo LED does not turn on, the user interface board may be faulty. Perform the User Interface Board Test Procedure. If any component tests faulty, replace the suspect component.

  • Page 32: Choke Test Procedure

    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.
  • Page 33 LINCOLN ELECTRIC FlexCut® 200 Service Manual Figure F.13 – Choke location Figure F.14 – Snubber board terminal B4 location...
  • Page 34 LINCOLN ELECTRIC FlexCut® 200 Service Manual Figure F.15 – Electrode terminal location...

  • Page 35: Thermostat Test Procedure

    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.
  • Page 36 LINCOLN ELECTRIC FlexCut® 200 Service Manual Figure F.16 – Switch board plug J25 location Figure F.17 – Switch board plug J25 lead locations...

  • Page 37: Auxiliary Rectifier (D4) Test Procedure

    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.
  • Page 38 LINCOLN ELECTRIC FlexCut® 200 Service Manual Figure F.18 – Auxiliary rectifier (D4) location Figure F.19 – Auxiliary rectifier (D4) test point and lead locations...

  • Page 39: User Interface Board Test Procedure

    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.
  • Page 40 LINCOLN ELECTRIC FlexCut® 200 Service Manual Table F.4 – User interface board LED functions LED # COLOR FUNCTION GREEN INPUT POWER CONNECTED +3.3V POWER SUPPLY “OK” GREEN +5V CAN POWER SUPPLY “OK” GREEN STATUS “OK” STATUS “ERROR” (CHECK CODE FOR SPECIFIC ERROR) GREEN +5V USB POWER “OK”...
  • Page 41 LINCOLN ELECTRIC FlexCut® 200 Service Manual Figure F.21 – User interface board plug J1 and LED locations Figure F.22 – User interface board plug J1 lead locations...

  • Page 42: Switch Board Test Procedure

    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.
  • Page 43 LINCOLN ELECTRIC FlexCut® 200 Service Manual Table F.6 – Switch board diode drop and resistance tests DESCRIPTION TEST POINT TEST POINT EXPECTED READING CONDITION (POS) (NEG) MACHINE “OFF” NO DIODE DROP TEST B209 (+) B204 (–) INPUT POWER APPLIED MACHINE “OFF” NO...
  • Page 44 LINCOLN ELECTRIC FlexCut® 200 Service Manual Table F.8 – Switch board LED functions LIGHT CONDITION MEANING STEADY GREEN SYSTEM OK. BLINKING GREEN OCCURS DURING STARTUP OR RESET AND INDICATES THAT THE SWITCH BOARD STATUS IS WAITING FOR COMMUICATION FROM THE USER INTERFACE BOARD.
  • Page 45 LINCOLN ELECTRIC FlexCut® 200 Service Manual Table F.9 – Switch board voltage tests TEST POINT TEST POINT EXPECTED DESCRIPTION CONDITION (POS) (NEG) READING INPUT POWER TO PLUG J19 PIN 3 PLUG J19 PIN 4 40 VDC MACHINE ON. SWITCH BOARD...
  • Page 46 LINCOLN ELECTRIC FlexCut® 200 Service Manual Figure F.23 – Switch board location Figure F.24 – Switch board plug and LED locations...
  • Page 47 LINCOLN ELECTRIC FlexCut® 200 Service Manual Figure F.25 – Electrode and work stud locations Figure F.26 – Pilot board terminal B3 location...
  • Page 48 LINCOLN ELECTRIC FlexCut® 200 Service Manual Figure F.27 – Switch board lead locations...

  • Page 49: Input Switch Test Procedure

    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.
  • Page 50 LINCOLN ELECTRIC FlexCut® 200 Service Manual Table F.10 – Input switch resistance tests TEST POINT TEST POINT EXPECTED READING SWITCH POSITION VERY LOW RESISTANCE “ON” POSITION (LESS THAN ONE OHM) VERY LOW RESISTANCE “ON” POSITION (LESS THAN ONE OHM) VERY LOW RESISTANCE “ON”...
  • Page 51 LINCOLN ELECTRIC FlexCut® 200 Service Manual Figure F.29 – Input switch terminal and lead locations Figure F.30 – Input switch positions...

  • Page 52: Solenoid 1, 2 And 3 Test Procedure

    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.
  • Page 53 LINCOLN ELECTRIC FlexCut® 200 Service Manual Table F.11 – Solenoid 1, 2 and 3 diode drop tests TEST POINTS (POS) TEST POINTS (NEG) EXPECTED READING PLUG J22 PIN 3 PLUG J22 PIN 8 .80 VDC (LEAD R1) (LEAD B1) PLUG J22 PIN 4 PLUG J22 PIN 9 .80 VDC...
  • Page 54 LINCOLN ELECTRIC FlexCut® 200 Service Manual Figure F.32 – Switch board plug J22 location Figure F.33 – Switch board plug J22 lead locations...

  • Page 55: Power Transformer (T1) Test Procedure

    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.
  • Page 56 LINCOLN ELECTRIC FlexCut® 200 Service Manual Table F.12 – Power transformer (T1) resistance tests DESCRIPTION TEST POINT TEST POINT EXPECTED READING SECONDARY WINDING SECONDARY WINDING LEAD X2 LEAD X4 VERY LOW RESISTANCE SECONDARY WINDING (DISCONNECTED FROM (DISCONNECTED FROM (LESS THAN ONE OHM)
  • Page 57 LINCOLN ELECTRIC FlexCut® 200 Service Manual Figure F.35 – Switch board terminals 201 and 204 locations...

  • Page 58: Voltage Divider Board Test Procedure

    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.
  • Page 59 LINCOLN ELECTRIC FlexCut® 200 Service Manual Table F.13 – Voltage divider board voltage tests TEST POINT (POS) TEST POINT (NEG) EXPECTED READING COMPONENT TESTED PLUG J1 PIN 3 PLUG J1 PIN 4 22 VDC ARC VOLTAGE INPUT (LEAD B3A) (LEAD B4A)
  • Page 60 LINCOLN ELECTRIC FlexCut® 200 Service Manual Figure F.37 – Voltage divider board plug and lead locations...

  • Page 61: Snubber Board Test Procedure

    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.
  • Page 62 LINCOLN ELECTRIC FlexCut® 200 Service Manual Table F.14 – Snubber board diode drop tests TEST POINT (POS) TEST POINT (NEG) EXPECTED READING DIODE TESTED .25V TO .70V A1 (DIODE) .25V TO .70V A2 (DIODE) A2 (DIODE) A1 (DIODE) .25V TO .70V A4 (DIODE) .25V TO .70V...
  • Page 63 LINCOLN ELECTRIC FlexCut® 200 Service Manual Figure F.39 – Snubber board terminal locations...

  • Page 64: Pilot Board Test Procedure

    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.
  • Page 65 LINCOLN ELECTRIC FlexCut® 200 Service Manual Table F.16 – Pilot board voltage tests TEST POINT TEST POINT EXPECTED DESCRIPTION CONDITION (POS) (NEG) READING INPUT POWER PLUG J1 PIN 16 PLUG J1 PIN 8 SUPPPLY FROM THE 15 VDC MACHINE ON.
  • Page 66 LINCOLN ELECTRIC FlexCut® 200 Service Manual Figure F.40 – Pilot board location Figure F.41 – Pilot board LED and plug locations...
  • Page 67 LINCOLN ELECTRIC FlexCut® 200 Service Manual Figure F.42 – Pilot board lead locations...

  • Page 68: Main Current Lem Test Procedure

    Locate plug J23 on the switch board. See Figure F.44. See Wiring Diagram. Carefully apply the correct input power to the FlexCut 200 and turn the machine ON. Using a volt/ohmmeter, carefully check for the DC supply voltages to the main current LEM per Table F.18.
  • Page 69 LINCOLN ELECTRIC FlexCut® 200 Service Manual Table F.18 – Main current LEM voltage tests DESCRIPTION TEST POINT (POS) TEST POINT (NEG) EXPECTED READING PLUG J23 PIN 1 PLUG J23 PIN 7 POSITIVE VOLTAGE SUPPLY +15 VDC (LEAD 231) (LEAD 237)
  • Page 70 LINCOLN ELECTRIC FlexCut® 200 Service Manual Figure F.43 – Main current LEM location Figure F.44 – Switch board plug J23 pin and lead locations...

  • Page 71: Pilot Current Lem Test Procedure

    Locate plug J23 on the switch board. See Figure F.46. See Wiring Diagram. Carefully apply the correct input power to the FlexCut 200 and turn the machine ON. Using a volt/ohmmeter, carefully check for the DC supply voltages to the pilot current LEM per Table F.20.
  • Page 72 LINCOLN ELECTRIC FlexCut® 200 Service Manual Table F.20 – Pilot current LEM voltage tests DESCRIPTION TEST POINT (POS) TEST POINT (NEG) EXPECTED READING PLUG J23 PIN 3 PLUG J23 PIN 9 POSITIVE VOLTAGE SUPPLY +15 VDC (LEAD 233) (LEAD 239)
  • Page 73 LINCOLN ELECTRIC FlexCut® 200 Service Manual Figure F.45 – Pilot current LEM location Figure F.46 – Switch board plug J23 pin and lead locations...

  • Page 74: Arclink I/O Board Test Procedure

    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.
  • Page 75 LINCOLN ELECTRIC FlexCut® 200 Service Manual Table F.22 – Arclink I/O board voltage tests DESCRIPTION TEST POINT TEST POINT EXPECTED READING INPUT VOLTAGE FROM PLUG J60 PIN 4 PLUG J60 PIN 3 40 VDC SWITCH BOARD (LEAD 52D) (LEAD 51D)
  • Page 76 LINCOLN ELECTRIC FlexCut® 200 Service Manual Figure F.47 – Arclink I/O board location Figure F.48 – Arclink I/O board plug and LED locations...
  • Page 77 LINCOLN ELECTRIC FlexCut® 200 Service Manual Figure F.49 – Arclink I/O board lead locations...

  • Page 78: Pressure Sense Board Test Procedure

    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.
  • Page 79 LINCOLN ELECTRIC FlexCut® 200 Service Manual Figure F.50 – Pressure sense board location Figure F.51 – Pressure sense board plug J4 location...
  • Page 80 LINCOLN ELECTRIC FlexCut® 200 Service Manual Figure F.52 – Pressure sense board lead locations...

  • Page 81: 40 Vdc Bus Board Test Procedure

    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.
  • Page 82 LINCOLN ELECTRIC FlexCut® 200 Service Manual Table F.25 – 40 VDC bus board voltage tests DESCRIPTION TEST POINT TEST POINT EXPECTED READING INPUT POWER FROM PLUG J1 PIN 1 PLUG J1 PIN 3 APPROX. 70 VDC AUXILIARY RECTIFIER (D4) (LEAD POS)
  • Page 83 LINCOLN ELECTRIC FlexCut® 200 Service Manual Figure F.54 – 40 VDC bus board LED and plug locations Figure F.55 – 40 VDC bus board lead locations...

  • Page 84: Removal And Replacement Procedures

    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.
  • Page 85 LINCOLN ELECTRIC FlexCut® 200 Service Manual 4. Connect leads 207, 209, L1A, L1B, L2A, L3A and H1 to the input rectifier (D1). See Wiring Diagram. 5. Using a 5/16” nutdriver, attach the five screws, lock washers and flat washers securing the leads to the input rectifier (D1).

  • Page 86: Auxiliary Transformer (T2) Removal And Replacement Procedure

    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.
  • Page 87 LINCOLN ELECTRIC FlexCut® 200 Service Manual 3. Using a Phillips screwdriver, attach the screw, lock washer and flat washer securing lead H1 to the input rectifier (D1). See Wiring Diagram. 4. Connect leads H4, H5 and H6 to the reconnect panel. See Wiring Diagram.
  • Page 88 LINCOLN ELECTRIC FlexCut® 200 Service Manual Figure F.59 – Auxiliary rectifier (D4) lead location Figure F.60 – Reconnect panel location...
  • Page 89 LINCOLN ELECTRIC FlexCut® 200 Service Manual Figure F.61 – Input rectifier (D1) lead H1 location Figure F.62 – Auxiliary transformer (T2) mounting hardware locations...

  • Page 90: Fan Removal And Replacement Procedure

    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.
  • Page 91 LINCOLN ELECTRIC FlexCut® 200 Service Manual REPLACEMENT PROCEDURE 1. Carefully position the new fan assembly into the machine. Note orientation and airflow. Direction of airflow is back to front. 2. Using a Torx nutdriver, attach the four screws securing the fan assembly to the rear of the machine.
  • Page 92 LINCOLN ELECTRIC FlexCut® 200 Service Manual Figure F.64 – Fan terminal connections Figure F.65 – Fan mounting screw locations...

  • Page 93: Choke Removal And Replacement Procedure

    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.
  • Page 94 LINCOLN ELECTRIC FlexCut® 200 Service Manual Figure F.66 – Snubber board terminal B4 location Figure F.67 – Electrode terminal location...
  • Page 95 LINCOLN ELECTRIC FlexCut® 200 Service Manual Figure F.68 – Choke mounting screws location...

  • Page 96: Thermostat Removal And Replacement Procedure

    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.
  • Page 97 LINCOLN ELECTRIC FlexCut® 200 Service Manual Figure F.69 – Thermostat removal...

  • Page 98: Auxiliary Rectifier (D4) Removal And Replacement Procedure

    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.
  • Page 99 LINCOLN ELECTRIC FlexCut® 200 Service Manual Figure F.70 – Auxiliary rectifier (D4) lead locations Figure F.71 – Auxiliary rectifier (D4) mounting nut location...

  • Page 100: User Interface Board Removal And Replacement Procedure

    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.
  • Page 101 LINCOLN ELECTRIC FlexCut® 200 Service Manual Figure F.72 – User interface board plug J1 location Figure F.73 – User interface board mounting hardware locations...

  • Page 102: Switch Board Removal And Replacement Procedure

    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.
  • Page 103 LINCOLN ELECTRIC FlexCut® 200 Service Manual 5. Connect plugs J19, J20, J21, J22, J23, J25, J26 and J28 to the switch board. See Wiring Diagram. Perform the Case Cover Replacement Procedure. 7. Perform the Retest After Repair Procedure. Figure F.74 – Switch board plug and lead locations...
  • Page 104 LINCOLN ELECTRIC FlexCut® 200 Service Manual Figure F.75 – Switch board mounting hardware locations...

  • Page 105: Input Switch Removal And Replacement Procedure

    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.
  • Page 106 LINCOLN ELECTRIC FlexCut® 200 Service Manual Figure F.76 – Input switch lead locations Figure F.77 – Input switch mounting hardware locations...

  • Page 107: Solenoid 1, 2 And 3 Removal And Replacement Procedure

    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.
  • Page 108 LINCOLN ELECTRIC FlexCut® 200 Service Manual 3. Using a Phillips screwdriver, attach the two screws and lock washers securing solenoid 3 to the vertical divider panel. 4. Using a 1/4” nutdriver, attach the two mounting nuts, lock washers and flat washers securing solenoid 3 to the vertical divider panel.
  • Page 109 LINCOLN ELECTRIC FlexCut® 200 Service Manual Figure F.79 – Solenoid mounting hardware locations Figure F.80 – Switch board plug J22 lead locations...

  • Page 110: Power Transformer (T1) Removal And Replacement Procedure

    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.
  • Page 111 LINCOLN ELECTRIC FlexCut® 200 Service Manual 2. Carefully position the new power transformer (T1) into the machine. 3. Using a 3/8” nutdriver, attach the two right side screws securing the transformer mounting bracket to the base of the machine. 4. Route leads X2 and X4 thru the previously disconnected cable grommet. See Wiring Diagram.
  • Page 112 LINCOLN ELECTRIC FlexCut® 200 Service Manual Figure F.82 – Transformer bracket mounting hardware location...

  • Page 113: Voltage Divider Board Removal And Replacement Procedure

    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.
  • Page 114 LINCOLN ELECTRIC FlexCut® 200 Service Manual Figure F.83 – Voltage divider board plug locations Figure F.84 – Voltage divider board mounting posts location...

  • Page 115: Snubber Board Removal And Replacement Procedure

    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.
  • Page 116 LINCOLN ELECTRIC FlexCut® 200 Service Manual 2. Using a Torx nutdriver (size T25), attach the four screws and lock washers securing each of the four IGBT modules to the heat sink. 3. Carefully position the new snubber board into the machine.
  • Page 117 LINCOLN ELECTRIC FlexCut® 200 Service Manual Figure F.86 – Snubber board mounting hardware locations Figure F.87 – IGBT module mounting hardware locations...
  • Page 118 LINCOLN ELECTRIC FlexCut® 200 Service Manual Figure F.88 – IGBT module Dow Corning application points...

  • Page 119: Pilot Board Removal And Replacement Procedure

    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.
  • Page 120 LINCOLN ELECTRIC FlexCut® 200 Service Manual Figure F.89 – Pilot board plug and lead locations Figure F.90 – Pilot board mounting hardware locations...

  • Page 121: Main Current Lem Removal And Replacement Procedure

    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.
  • Page 122 LINCOLN ELECTRIC FlexCut® 200 Service Manual Perform the Case Cover Replacement Procedure. 7. Perform the Retest After Repair Procedure. Figure F.91 – Main current LEM mounting hardware locations Figure F.92 – Main current LEM orientation...

  • Page 123: Pilot Current Lem Removal And Replacement Procedure

    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.
  • Page 124 LINCOLN ELECTRIC FlexCut® 200 Service Manual Perform the Case Cover Replacement Procedure. 7. Perform the Retest After Repair Procedure. Figure F.93 – Pilot current LEM mounting hardware locations Figure F.94 – Pilot current LEM orientation...

  • Page 125: Arclink I/O Board Removal And Replacement Procedure

    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.
  • Page 126 LINCOLN ELECTRIC FlexCut® 200 Service Manual Figure F.95 – Arclink I/O board plug locations Figure F.96 – Arclink I/O board mounting hardware locations...

  • Page 127: Pressure Sense Board Removal And Replacement Procedure

    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.
  • Page 128 LINCOLN ELECTRIC FlexCut® 200 Service Manual Figure F.97 – Pressure sense board hose and plug locations...

  • Page 129: 40 Vdc Bus Board Removal And Replacement Procedure

    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.
  • Page 130 LINCOLN ELECTRIC FlexCut® 200 Service Manual Figure F.98 – 40 VDC bus board plug locations Figure F.99 – 40 VDC bus board mounting hardware locations...

  • Page 131: Isotop Igbt Removal And Replacement Procedure

    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.
  • Page 132 LINCOLN ELECTRIC FlexCut® 200 Service Manual Figure F.100 – Isotop IGBT mounting hardware locations Figure F.101 – Isotop IGBT orientation...

  • Page 133: Retest After Repair

    2. Turn on the machine and verify the following: • The fan is functional. • The user interface screen is illuminated. Test cut with FlexCut 200 at its maximum recommended cut thickness with 1.5” steel max. Turn current dial to maximum. 4. Turn the machine off. Test complete.

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