Lincoln Electric PRO-CUT 60 SVM104-A Service Manual
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Lincoln Electric PRO-CUT 60 SVM104-A Service Manual

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P P R R O O - - C C U U T T
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
READING THIS MANUAL AND
THE SAFETY PRECAUTIONS
CONTAINED
THROUGHOUT.
And, most importantly, think before
you act and be careful.
World's Leader in Welding and Cutting Products
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
RETURN TO MAIN INDEX
For use with machines having Code Numbers:
SERVICE MANUAL
• Sales and Service through Subsidiaries and Distributors Worldwide •
™
6 6 0 0
( ( S S i i n n g g l l e e P P h h a a s s e e ) )
9819, 10096, 10112
10118, 10217, 10218
10393, 10394
ON
ON
OF F
OF F
Premier Manufacturer of Industrial Motors
SVM104-A
March, 1999
o
o
1
1

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Summary of Contents for Lincoln Electric PRO-CUT 60 SVM104-A

  • Page 1 P P R R O O - - C C U U T T For use with machines having Code Numbers: 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 ...

  • Page 2: Electric Shock Can Kill

    Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PER- FORMED ONLY BY QUALIFIED INDIVIDUALS.

  • Page 3: Safety

    WELDING OR CUTTING SPARKS can cause fire or explosion. 4.a. Remove fire hazards from the welding or cut- ting area. If this is not possible, cover them to prevent the welding or cutting sparks from start- ing a fire. Remember that welding or cutting sparks and hot materials from welding or cutting can easily go through small cracks and openings to adjacent areas.
  • Page 4 FOR ENGINE powered equipment. 7.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 7.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. ____________________________________________________ 7.c. Do not add the fuel near an open flame welding or cutting arc or when the engine is running.
  • Page 5 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a.

  • Page 6: Table Of Contents

    MASTER TABLE OF CONTENTS FOR ALL SECTIONS Safety ...iv Installation ...Section A Technical Specifications ... A-1 Safety Precautions ... A-2 Select Proper Location ...A-2 High Frequency Interference Protection...A-2 Input Electrical Connections ... A-3 Reconnect Procedure ... A-6 Output Connections ... A-7 Operation ...Section B Operating Instructions ...
  • Page 7 TABLE OF CONTENTS - INSTALLATION SECTION - Installation ... Section A Technical Specifications ... A-1 Safety Precautions ... A-2 Select Proper Location...A-2 Stacking ...A-2 Tilting...A-2 High Frequency Interference Protection ...A-2 Input Electrical Connections ... A-3 Fuses and Wire Sizes ...A-4 Ground Connection ...

  • Page 8: Installation

    TECHNICAL SPECIFICATIONS - PRO-CUT 60 INPUT - SINGLE PHASE / 60 HERTZ ONLY Standard Voltage 208/230/460 460/575 Duty Cycle 60% Duty Cycle 100% Duty Cycle Current Range 25-60 Amps RECOMMEND INPUT WIRE AND FUSE SIZES Based on U.S. National Electrical Code AC Input Voltage at (Super Lag)

  • Page 9: Safety Precautions

    Read entire Installation Section before installing the PRO-CUT 60. SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK CAN KILL. • Only qualified personnel should install this machine. • Turn the input power OFF at the disconnect switch or fuse box before working on the equipment.

  • Page 10: Input Electrical Connections

    3. Connect the work terminal to a ground within ten feet of the machine. a. Use grounding cable that is the same size as, or larger than, the work cable. b. Make grounding cable as short as possible. c. Connect the ground tightly. Use one of the following ground methods: (1) Connect to a metal underground water pipe that is in direct contact with earth for...

  • Page 11: Fuses And Wire Sizes

    FUSE AND WIRE SIZES Protect the input circuit with the super lag fuses or delay type circuit breakers listed on the Specifications page of this manual for the machine being used. The tripping action of delay type circuit breakers decreases as the magnitude of the current increases.

  • Page 12: Air Input Connections

    AIR INPUT CONNECTIONS Supply the PRO-CUT 60 with clean compressed air or nitrogen. • Supply pressure must be between 70 psi and 120 psi (482 kPa and 827 kPa). • Flow rate should be approximately 4.7 cfm (133 I/min.). NOTE: Oil in the air supply to the PRO-CUT 60 can cause severe problems.

  • Page 13: Reconnect Procedure

    RECONNECT PROCEDURE Multiple voltage machines are shipped connected to the highest input voltage listed on the machine's rating plate. Before installing the machine, check that the Reconnect Panel in the Input Box Assembly is connected for the proper voltage. CAUTION Failure to follow these instructions can cause immediate failure of components within the machine.

  • Page 14: Output Connections

    OUTPUT CONNECTIONS WARNING To avoid receiving a high frequency shock, keep the torch and cables in good condition. __________________ The standard PRO-CUT 60 cutting torch comes with a 25 ft. (7.6m) cable. A cutting torch with a 50 ft. (15.2m) cable is available. The PRO-CUT 60 is shipped with the torch and work cables already connected.

  • Page 15: General Description

    TABLE OF CONTENTS - OPERATION SECTION - Operation ...Section B Safety Precautions ... B-1 General Description ... B-2 Recommended Processes and Equipment ...B-2 Operational Features and Controls ...B-2 Design Features and Advantages ...B-2 Cutting and Gouging Capability ... B-3 Limitations ...B-3 Controls and Settings ...B-3 Operating Steps ...

  • Page 16: Operation

    SAFETY PRECAUTIONS - Observe additional Safety Guidelines detailed in the beginning of this manual. PRO-CUT 60 OPERATION Read and understand entire section before operating machine. WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet clothing.

  • Page 17: General Description

    GENERAL DESCRIPTION The PRO-CUT 60 is a constant current, single range, continuous control plasma cutting system. The microprocessor-based PRO-CUT 60 is capa- ble of cutting with compressed air or nitrogen gas. Nitrogen gas is used to cut aluminum or other non-ferrous metals.

  • Page 18: Cutting And Gouging Capability

    • Works with pure nitrogen for cutting non-ferrous metal. • Smart switching of pilot contactor so that it does not switch under load. • Low fan noise at idle. • Modular construction for easy servicing. CUTTING AND GOUGING CAPABILITY The PRO-CUT 60 is rated at 60 amps, 115 VAC, at 60% duty cycle on a 10 minute basis or 45 amps, 115VAC, at 100% duty cycle.

  • Page 19: Operating Steps

    1. Safety Reset Button, 4. Output Current Control, OPERATING STEPS When preparing to cut or gouge, position the machine as close to the work as possible. Make sure you have all materials needed to complete the job and have taken all safety precautions. It is important to follow these operating steps each time you use the machine.

  • Page 20: Cutting Procedure Recommendations

    8. Pull the torch trigger to cut. - OUTPUT ON LED glows. If postflow has not timed out, the pilot arc lights immediately. If postflow air has timed out (after 20 sec- onds), air preflows for two seconds before pilot arc lights. If the arc is not transferred by bringing plasma in contact with the work with in 2.5 seconds, the pilot arc shuts off.
  • Page 21 6. Use nozzle with the largest orifice that gives the best cut for the work being done. This pro- duces the best work results and consumable life. As the size of the nozzle orifice increases, its current capability increases. Therefore, the nozzle used for cutting or gouging work must be able to handle the current needed to give the best cutting results.

  • Page 22: Cutting Expanded Metal

    Cutting Expanded Metal 1. Cut expanded metal with CURRENT CONTROL set near the mid- range position using the same methods listed under Cutting Thin Gauge Metal. Keep the following points in mind: a. Place a thin piece of scrap metal over the area to be cut and then cut through both to make cutting easier.

  • Page 23: Gouging Metal

    Gouging Metal 1. Set the OUTPUT CURRENT CONTROL to maximum. 2. Use the plasma torch with a S24114 Drag Cup assembly or a S24162 shield cup. 3. Bring the torch slowly towards the work piece at a 30 angle, but do not pierce the work piece.
  • Page 24 NOTES PRO-CUT 60...

  • Page 25: Accessories

    TABLE OF CONTENTS Section C - ACCESSORIES SECTION - Page Accessories... Section C Accessories...C-1 PRO-CUT 60...

  • Page 26: Accessories

    OPTIONS/ACCESSORIES DRAG CUP ASSEMBLY (S24114) The drag cup protects the torch by preventing the torch from touching the workpiece. SHIELD CUP ASSEMBLY (S24162) This shields the torch tip and provides more visibil- ity to the workpiece than the drag cup. Note the shield cup does not prevent the torch tip from touching the workpiece.

  • Page 27: Routine And Periodic Maintenance

    TABLE OF CONTENTS Section D - MAINTENANCE SECTION - Page Maintenance ... Section D Safety Precautions ...D-1 Capacitor Discharge Procedure ...D-1 - D-2 Routine and Periodic Maintenance ...D-3 3-D Exploded View...D-4 PRO-CUT 60...
  • Page 28 SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. CAPACITOR DISCHARGE PROCEDURE PROCEDURE DESCRIPTION This procedure must be performed before per- forming any maintenance inside the machine. MATERIALS NEEDED High resistance, high wattage resistor Insulated pliers Insulated gloves DC Volt/Ohm meter (Multimeter) PRO-CUT 60 MAINTENANCE WARNING •...
  • Page 29 CAPACITOR DISCHARGE PROCEDURE PROCEDURE NOTE: See Figure D.1. 1. Disconnect input power to the machine. 2. Remove the Left Case Side Assembly. 3. Locate the two capacitors shown Figure D.1 and D.2. 4. Put on the insulated gloves. 5. Grip the middle of the resistor with the insulated pliers.

  • Page 30: Maintenance

    ROUTINE AND PERIODIC MAINTENANCE 1. Disconnect input power supply lines to the machine before performing periodic main- tenance, tightening, cleaning, or replacing parts. See Figure D.2. 2. Perform Capacitor Discharge Procedure Perform the following daily: 1. Check that no combustible materials are in the cutting or gouging area or around the machine.
  • Page 31 MAINTENANCE CASE FRONT ASSEMBLY CASE BACK ASSEMBLY INPUT BOX ASSEMBLY CONTROL PANEL ASSEMBLY HIGH FREQUENCY BOARD ASSEMBLY BASE ASSEMBLY CAPACITOR BANK FIGURE D.2 - General Assembly Exploded View PRO-CUT 60...
  • Page 32 NOTES PRO-CUT 60...

  • Page 33: Thermal Protection

    TABLE OF CONTENTS - THEORY OF OPERATION SECTION - Theory of Operation Section ... Section E Power Supply Operation ...E-1 - E-4 Input Line Voltage and Main Transformer...E-1 Output Rectification...E-2 High Voltage / High Frequency and By-Pass Circuit ...E-3 Pilot Arc ...E-4 Transistor Switching Operation...E-5 PWM Operation and Thermal Protection ...

  • Page 34: Theory Of Operation

    FIGURE E.2. - Input Line Voltage and Main Transformer INPUT LINE VOLTAGE AND MAIN TRANSFORMER The desired single-phase input power is connect- ed to the Pro-Cut 60 through a line switch located on the front panel of the machine. A reconnect panel allows the user to configure the machine for the desired input voltage.

  • Page 35: Output Rectification

    FIGURE E.3 - Output Rectification, Control and Feedback OUTPUT RECTIFICATION, CONTROL AND FEEDBACK The AC output from the main transformer sec- ondary is rectified through the SCR/ DIODE bridge. The machine output is controlled through the transistor module. The output current is sensed at the shunt, as a low voltage signal, and fed back to the control board.

  • Page 36: High Voltage / High Frequency And By-Pass Circuit

    FIGURE E.4 - High Voltage/High Frequency and By-Pass Circuit HIGH VOLTAGE / HIGH FREQUENCY AND BY-PASS CIRCUIT The control board passes the 115vac through the CR2 relay contacts to the primary of the high volt- age transformer. The secondary of the high volt- age transformer delivers a high voltage to the spark gap generator and also to the high frequen- cy transformer.

  • Page 37: Pilot Arc

    PILOT ARC The Pro-Cut 60 has a smooth, continuous pilot arc. The pilot arc is a means of establishing and transferring the arc to the work piece for cutting. The pilot arc current flow is from the positive potential work terminal through the R2 resistor and CR2 contacts to the pilot lead circuit in the torch cable.

  • Page 38: Transistor Switching Operation

    FIGURE E.7 - Transistor Switching Operation TRANSISTOR SWITCHING OPERATION A transistor is a solid state device consisting of three layers of silicon crystal. These three layers form the emitter, collector and base regions of a transistor. They are used at high frequencies in high power applications and switching circuits.

  • Page 39: Pulse Width Modulation

    FIGURE E.8 - Pulse Width Modulation PULSE WIDTH MODULATION The term PULSE WIDTH MODULATION is used to describe how much of a given time period is devoted to conduction(collector current flow). Changing the pulse width, within a given time peri- od, is known as MODULATION.
  • Page 40 NOTES PRO-CUT 60...
  • Page 41 TABLE OF C - TROUBLESHOOTING & REPAIR SECTION - Troubleshooting & Repair Section...Section F Safety Precautions...F-1 How to Use Troubleshooting Guide...F-1 PC Board Troubleshooting Procedures ...F-2 Troubleshooting Guide ...F-3 - F-11 Control and Power Board Connector Locations ...F-12 Test Procedures Capacitor Discharge Procedure...F-13 - F-14 Torch, Torch Cable Assembly, Internal Trigger &...

  • Page 42: Troubleshooting And Repair

    TROUBLESHOOTING & REPAIR HOW TO USE TROUBLESHOOTING GUIDE Service and Repair should only be performed by 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 43: Pc Board Troubleshooting Procedures

    TROUBLESHOOTING PC BOARD TROUBLESHOOTING PROCEDURES WARNING ELECTRIC SHOCK can kill. Have an electrician install and service this equipment. Turn the input power OFF at the fuse box before working on equipment. Do not touch electrically hot parts. CAUTION: Sometimes machine failures appear to be due to PC board failures.

  • Page 44: Troubleshooting Guide

    TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Major Physical or Electrical Damage is Evident LEDs light when ON/OFF Power Switch turned "ON". Machine is dead. Fan is not running. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216-383-2531 or 1-800-833-9353.
  • Page 45 TROUBLESHOOTING & REPAIR Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) LEDs light when ON/OFF Power Switch is turned "ON". Machine is dead. Fan runs normally. The "MACHINE ON" LED is lit and the "SAFETY" LED is lit. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216-383-2531 or 1-800-833-9353.
  • Page 46 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) The air begins to flow, the "OUTPUT ON" LED lights for a short time, but no pilot arc is established. The high frequen- cy arc does NOT appear across the torch tip. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216-383-2531 or 1-800-833-9353.
  • Page 47 TROUBLESHOOTING & REPAIR Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) The air begins to flow, the "OUTPUT ON" LED lights for a short time, but no pilot arc is established. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216-383-2531 or 1-800-833-9353.
  • Page 48 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) The "THERMAL" LED is lit. "MALFUNCTION" "FAULT" LED is blinking. The machine has no output. "MALFUNCTION" "FAULT" LED is lit. machine has no output. When the torch trigger is pulled the "OUTPUT ON" LED lights for a very short period of time.
  • Page 49 TROUBLESHOOTING & REPAIR Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) The "OUTPUT ON" and "MAL- FUNCTION" or "FAULT" LED's blink in alternating order. No pilot arc. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216-383-2531 or 1-800-833-9353.
  • Page 50 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Airflow does not shut off. The "OUTPUT ON" and "AIR PRESSURE" LED's blink in alternating order. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216-383-2531 or 1-800-833-9353.
  • Page 51 TROUBLESHOOTING & REPAIR Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) The "MACHINE ON" LED is lit but there is no response when the torch trigger is pulled. The "AIR PRESSURE" LED does not turn on. The fan runs nor- mally.
  • Page 52 F-11 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) The arc starts but sputters badly. (If cutting expanded metal, condition may be nor- mal, see operation section.) "MALFUNCTION" "FAULT" LED starts blinking during cutting or gouging. Pilot arc is OK but cutting arc will not establish.
  • Page 53 TROUBLESHOOTING & REPAIR CONTROL BOARD CONNECTOR LOCATION 8J5 7J5 6J10 FIGURE F.1 - Control Board Connector Locations POWER BOARD CONNECTOR LOCATION MOUNTING SCREWS LEAD 4J20 LEAD 2J20 LEADS LEAD 3J22 LEADS 4J22 FIGURE F.2 - Power Board Connector Locations 6J5 5J5 1J21 1J20 1J22...

  • Page 54: Capacitor Discharge Procedure

    TROUBLESHOOTING & REPAIR CAPACITOR DISCHARGE PROCEDURE Service and repair should be performed only by Lincoln Electric factory trained per- sonnel. Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and pre- cautions detailed throughout this manual.
  • Page 55 TROUBLESHOOTING & REPAIR CAPACITOR DISCHARGE PROCEDURE PROCEDURE NOTE: See Figure F.19. 1. Disconnect input power to the machine. 2. Remove the Left Case Side Assembly. 3. Locate the two capacitors shown in Figure F.19. 4. Put on the insulated gloves. 5.

  • Page 56: Torch, Torch Cable Assembly, Internal Trigger & Safety Circuit Test

    TORCH, TORCH CABLE ASSEMBLY, INTERNAL TRIGGER, AND SAFETY CIRCUIT TEST Service and repair should be performed only by Lincoln Electric factory trained per- sonnel. Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and pre- cautions detailed throughout this manual.
  • Page 57 Test for a voltage across the stud marked WORK and the bulkhead connector (brass fitting). voltage should be present. If a voltage is present, STOP. NOT perform this test. Contact the Lincoln Electric Service Department. If no voltage is present, continue test procedure. PILOT WORK...
  • Page 58 F-17 TROUBLESHOOTING & REPAIR TORCH, TORCH CABLE ASSEMBLY, INTERNAL TRIGGER, AND SAFETY CIRCUIT TEST d. Disconnect the trigger lead 4-pin connector by unscrewing it. e. Disconnect the electrode lead using a 9/16” open-end wrench to remove the brass adaptor fit- ting attached to the bulkhead connector.
  • Page 59 TROUBLESHOOTING & REPAIR TORCH, TORCH CABLE ASSEMBLY, INTERNAL TRIGGER, AND SAFETY CIRCUIT TEST c. If any of the above tests do not agree with the expected normal resistance specifications, then the torch and/or cable must be repaired or replaced. CONDUCTOR IN GAS TUBE ELECTRODE #336 24 VAC...
  • Page 60 F-19 TROUBLESHOOTING & REPAIR TORCH, TORCH CABLE ASSEMBLY, INTERNAL TRIGGER, AND SAFETY CIRCUIT TEST 8. Disconnect Plug J5 from its header on the Control Board. 9. Test for zero ohms (continuity) from the following test points on Plug J5 header to the 4-pin leads on the bulkhead of the machine (See Figure F.7): - Pin 4J5 (lead #4) to 4-pin pin...
  • Page 61 TROUBLESHOOTING & REPAIR TORCH, TORCH CABLE ASSEMBLY, INTERNAL TRIGGER, AND SAFETY CIRCUIT TEST CONTROL PC BOARD 4 - PIN RECEPTACLE FIGURE F.6-Control Board and 4-pin Locations. 4- PIN RECEPTACLE IN BULKHEAD FIGURE F.7-Control Board and 4-Pin Connector Test Points REMOVE J5 PLUG F-20 PRO-CUT 60...

  • Page 62: Transistor Module Test

    TROUBLESHOOTING & REPAIR TRANSISTOR MODULE TEST Service and repair should be performed only by Lincoln Electric factory trained per- sonnel. Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and pre- cautions detailed throughout this manual.
  • Page 63 TROUBLESHOOTING & REPAIR TRANSISTOR MODULE TEST MATERIALS NEEDED - Analog Volt/Ohmmeter (Multimeter) with RX10 or RX1000 scale. - PRO-CUT 60 Wiring Diagrams - Phillips Head Screwdriver TEST PROCEDURE 1. Turn ON/OFF Power Switch to OFF. 2. Disconnect main input power to machine.
  • Page 64 F-23 TROUBLESHOOTING & REPAIR TRANSISTOR MODULE TEST 10. Replace the terminal screw snugly, a little more than finger tight. The Transistor Module is mounted behind the Power Board and the terminal screw completes connection. 11. Perform the following resi- tance tests listed in Table F.1: NOTE: Meter lead polarity must be observed for these resistance tests.

  • Page 65: Main Transformer Test

    TROUBLESHOOTING & REPAIR MAIN TRANSFORMER TEST Service and repair should be performed only by Lincoln Electric factory trained per- sonnel. Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and pre- cautions detailed throughout this manual.
  • Page 66 F-25 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER TEST TEST PROCEDURE 1. Connect main supply to machine. NOTE: When performing Tests A and a. If any one voltage is missing or below the specification, inspect the associated plugs and wiring. If there are no loose plugs or wiring, then winding in the main transformer...
  • Page 67 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER TEST CONTROL PC BOARD POWER PC BOARD FIGURE F.10 Main Transformer Test Components TOUCH METER PROBE TO LEAD #31 CONNECTED TO THE COIL OF THE CONTACTOR FIGURE F.10A CR2 Lead Locations for Table F.2. F-26 CONTROL RELAY (CR2)

  • Page 68: Power Board Test

    F-27 TROUBLESHOOTING & REPAIR Service and repair should be performed only by Lincoln Electric factory trained per- sonnel. Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and pre- cautions detailed throughout this manual.
  • Page 69 TROUBLESHOOTING & REPAIR POWER BOARD TEST MOUNTING LEAD LEAD LEADS LEAD LEADS FIGURE F.11-Power Board Test Points TEST PROCEDURE 1. Connect input power machine. 2. Turn ON/OFF Power Switch to OFF. Test A: Test for 12 VAC voltage to Power Board 1.
  • Page 70 F-29 TROUBLESHOOTING & REPAIR Test B: Test for 7 VDC signal between Power Board and Control Board NOTE: This test requires that the torch trigger be pulled to activate the circuit. Be sure to use an isolated meter because of the high voltage and high frequency produced.
  • Page 71 TROUBLESHOOTING & REPAIR POWER BOARD TEST Test D: Test for 0.2 VDC to 0.3 VDC Gate Drive Voltages to the SCR Module. NOTE: This test requires that the torch trigger be pulled to activate the circuit. Be sure to use an isolated meter because of the high voltage and high frequency produced.

  • Page 72: High Voltage Transformer And Circuit Test

    TROUBLESHOOTING & REPAIR HIGH VOLTAGE TRANSFORMER AND CIRCUIT TEST Service and repair should be performed only by Lincoln Electric factory trained per- sonnel. Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and pre- cautions detailed throughout this manual.
  • Page 73 TROUBLESHOOTING & REPAIR HIGH VOLTAGE TRANSFORMER AND CIRCUIT TEST CONTROL RELAY (CR2) HIGH VOLTAG E TRANSFORMER HIGH FREQU ENCY BOARD FIGURE F.12-High Voltage Test Component Locations TEST PROCEDURE NOTE: This test can be performed best with alligator clips used with the meter probes.
  • Page 74 F-33 TROUBLESHOOTING & REPAIR HIGH VOLTAGE TRANSFORMER AND CIRCUIT TEST Test B: Test Resistance of High Voltage Transformer Primary 1. Disconnect machine. 2. Turn ON/OFF Power Switch to OFF. 3. Perform DISCHARGE PROCEDURE. 4. Locate and touch probes to lead #31 and lead #35 on the Control Relay CR2.

  • Page 75: On/Off Power Switch Removal

    TROUBLESHOOTING & REPAIR ON/OFF POWER SWITCH REMOVAL Service and repair should be performed only by Lincoln Electric factory trained per- sonnel. Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and pre- cautions detailed throughout this manual.
  • Page 76 F-35 TROUBLESHOOTING & REPAIR ON/OFF POWER SWITCH REMOVAL (LATER CODES MAY HAVE TOGGLE SWITCH) ON/OFF POWER SWITCH KNOB SCREW (SECURING KNOB) FACE PLATE SCREWS (SECURING FACE PLATE) SWITCH L1 & L2 LEADS T1 & T2 LEADS FIGURE F.13-ON/OFF Power Switch Removal/Replacement REMOVAL/REPLACEMENT PROCEDURE 1.

  • Page 77: Control Board Removal

    TROUBLESHOOTING & REPAIR CONTROL BOARD REMOVAL Service and repair should be performed only by Lincoln Electric factory trained per- sonnel. Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and pre- cautions detailed throughout this manual.
  • Page 78 F-37 TROUBLESHOOTING & REPAIR CONTROL BOARD REMOVAL REMOVAL/REPLACEMENT PROCEDURE 1. Disconnect input power to the machine. 2. Remove the Left Case Side assembly. 3. Perform DISCHARGE PROCEDURE. 4. Remove the seven Molex plugs from their headers and position out of the way. See Figure F.1. 5.

  • Page 79: Power Board Removal

    TROUBLESHOOTING & REPAIR POWER BOARD REMOVAL Service and repair should be performed only by Lincoln Electric factory trained per- sonnel. Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and pre- cautions detailed throughout this manual.
  • Page 80 F-39 TROUBLESHOOTING & REPAIR LEAD LEAD LEADS LEAD LEADS FIGURE F.14-Power Board Removal/Replacement REMOVAL/REPLACEMENT PROCEDURE 1. Disconnect input power to the machine. 2. Remove the Left Case Side Assembly. 3. Perform DISCHARGE PROCEDURE. 4. Remove the Molex Plugs J20, J21, and J22 from the Power Board.
  • Page 81 TROUBLESHOOTING & REPAIR POWER BOARD REMOVAL 8. Remove four mounting Phillips head screws holding the Power Board module. 9. Remove the two nylon nuts from the studs on which the Power Board is mounted with a 7/16” nut driver. 10. Remove the Power Board by pulling it out clear of the studs and lifting it straight up out of the machine.

  • Page 82: Transistor Module Removal

    TROUBLESHOOTING & REPAIR TRANSISTOR MODULE REMOVAL Service and repair should be performed only by Lincoln Electric factory trained per- sonnel. Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and pre- cautions detailed throughout this manual.
  • Page 83 TROUBLESHOOTING & REPAIR TRANSISTOR MODULE REMOVAL REMOVAL/REPLACEMENT PROCEDURE NOTE: It is recommended that when the Transistor Module is replaced, the Power Board and the Control Board should be replaced. NOTE: See Figure F.15. 1. Disconnect input power to the machine. 2.

  • Page 84: Scr Module Removal

    F-43 TROUBLESHOOTING & REPAIR Service and repair should be performed only by Lincoln Electric factory trained per- sonnel. Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and pre- cautions detailed throughout this manual.
  • Page 85 TROUBLESHOOTING & REPAIR SCR MODULE REMOVAL SOCKET HEAD CAP SCREWS TORQUE TO 35 IN/LBS (3.9 N/M) FIGURE F.16-SCR Module Location with Power Board Removed REMOVAL/REPLACEMENT PROCEDURE NOTE: See Figure F.16. 1. Disconnect input power to the machine. 2. Remove the Left Case Side assembly.
  • Page 86 F-45 TROUBLESHOOTING & REPAIR b. Rinse the heat sink surface with alcohol or acetone. c. Apply a .002” to .005” coat of joint compound evenly to the heat sink mounting surface mounting Lincoln T12837, or equivalent, such as Dow Corning #340. d.

  • Page 87: Fan Blade And Fan Motor Removal/Replacement

    TROUBLESHOOTING & REPAIR FAN BLADE AND FAN MOTOR REMOVAL/REPLACEMENT Service and repair should be performed only by Lincoln Electric factory trained per- sonnel. Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and pre- cautions detailed throughout this manual.
  • Page 88 F-47 TROUBLESHOOTING & REPAIR FAN BLADE AND FAN MOTOR REMOVAL/REPLACEMENT FIGURE F.17-Fan Blade & Fan Motor REMOVAL/REPLACEMENT PROCEDURE NOTE: See Figure F.17. 1. Disconnect input power to the machine. 2. Perform DISCHARGE PROCEDURE. 3. Disconnect the air line to the air regulator on the Case Back Assembly.
  • Page 89 TROUBLESHOOTING & REPAIR FAN BLADE AND FAN MOTOR REMOVAL/REPLACEMENT 9. Pull the rubber air line hose into the machine out of the rubber grommet. Be sure to keep the Case Back Assembly support- ed. Allow it to lean out away from the machine at about a 45 angle so you have plenty of room to work on the fan blade...

  • Page 90: Torch Head Removal/Replacement

    TROUBLESHOOTING & REPAIR TORCH HEAD REMOVAL/REPLACEMENT Service and repair should be performed only by Lincoln Electric factory trained per- sonnel. Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and pre- cautions detailed throughout this manual.
  • Page 91 TROUBLESHOOTING & REPAIR TORCH HEAD REMOVAL/REPLACEMENT 4-PIN CONNECTOR ELECTRODE LEAD PILOT LEAD PHILLIPS HEAD SCREW HANDLE SAFETY LEADS BRASS COMPRESSION NUT CABLE STRAIN RELIEF ALIGNMENT HOLE FIGURE F.18-Torch Head Removal/Replacement REMOVAL/REPLACEMENT PROCEDURE NOTE: See Figure F.18. 1. Disconnect input power to the machine.
  • Page 92 F-51 TROUBLESHOOTING & REPAIR TORCH HEAD REMOVAL/REPLACEMENT d. Disconnect the trigger lead 4-pin unscrewing it. e. Disconnect the electrode lead using a 9/16” open- end wrench to remove the brass attached to the bulkhead connector. Disconnect the pilot lead by removing marked PILOT.

  • Page 93: Retest After Repair

    TROUBLESHOOTING & 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 replaced, the machine must be retested.
  • Page 94 F-53 NOTES PRO-CUT 60...
  • Page 95 TABLE OF CONTENTS Section G - ELECTRICAL DIAGRAMS - Page Electrical Diagrams ... Section G Status Board Schematic (M15601)...G-2 Bypass Board Schematic (M15603) ...G-3 Bypass Board Schematic (M17322) ...G-4 Control Board Components (G2015) ...G-6 Power Board Components(L7941) ...G-8 Status Board Components (M15601) ...G-10 Bypass Board Components (M15603)...G-12 Bypass Board Components (M17322)...G-14 Wiring Diagram (Codes 10112, 10118)...G-16...
  • Page 96 PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric dis- courages 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.
  • Page 97 PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric dis- courages 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.
  • Page 98 PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric dis- courages 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.
  • Page 99 NOTES PRO-CUT 60...

  • Page 100: Control Board

    PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric dis- courages 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.

  • Page 101: Electrical Diagrams

    PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric dis- courages 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.
  • Page 102 PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric dis- courages 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.
  • Page 103 PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric dis- courages 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.
  • Page 104 PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric dis- courages 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.
  • Page 105 PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric dis- courages 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.
  • Page 106 PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric dis- courages 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.
  • Page 107 PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric dis- courages 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.
  • Page 108 PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric dis- courages 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.
  • Page 109 PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric dis- courages 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.
  • Page 110 3 1 9 3 2 4 3 2 3 3 2 2 3 1 9 3 2 1 P U R G E / R U N S W I T C H ( P U R G E I S O P E N ) 3 1 9 5 J 1 2...
  • Page 111 WIRING DIAGRAM FOR CODES 9819, 10096 S T A T U S B O A R D 1 2 3 2 1 2 2 1 4 2 1 6 2 1 1 2 1 3 2 1 5 2 1 8 7 8 4 9 1 0 1 1 3 1 9...
  • Page 112 + 2 4 V + 1 5 V + 1 8 A 5 m H O U T 5 m H D 1 0 D Z 7 1 7 V G N D C 5 8 + 1 8 A P H 3 .
  • Page 113 NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician.
  • Page 114 Your Company__________________________ Your Name_____________________________ Please give detailed description below: ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ SD287 01/99 Thank You, Technical Services Group Lincoln Electric Co. 22801 ST. Clair Ave. Cleveland, Ohio 44117-1199 FAX 216-481-2309...

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