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Lincoln Electric PRO-CUT 25 SVM149-A Service Manual

Lincoln electric welder user manual
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RETURN TO MAIN MENU
SVM149-A
October, 2006
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

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

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Summary of Contents for Lincoln Electric PRO-CUT 25 SVM149-A

  • Page 1: Service Manual

    RETURN TO MAIN MENU SVM149-A October, 2006 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 .

  • Page 2: Safety

    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. For additional safety information it is strongly recommended that you pur- chase a copy of “Safety in Welding &...
  • Page 3 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.
  • Page 4 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 5: Table Of Contents

    MASTER TABLE OF CONTENTS FOR ALL SECTIONS Safety ...i-iii Installation ...Section A Technical Specifications ...A-2 Safety Precautions...A-3 Select Proper Location ...A-3 Stacking ...A-3 Tilting...A-3 High Frequency Interference Protection...A-3 Input Electrical Connections...A-3 Gas Input Connections ...A-4 Output Connections...A-5 Torch ...A-5 Operation...Section B Safety Precautions ...B-2 Description ...B-2 Preheating Temperature ...B-2...
  • Page 6 NOTES PRO-CUT 25...

  • Page 7: Installation Section

    Section A-1 Section A-1 TABLE OF CONTENTS - INSTALLATION SECTION - Installation Technical Specifications ...A-2 Safety Precautions...A-3 Select Proper Location ...A-3 Stacking ...A-3 Tilting ...A-3 High Frequency Interference Protection...A-3 Input Electrical Connections...A-3 Gas Input Connections...A-4 Output Connections ...A-5 Torch ...A-5 PRO-CUT 25...

  • Page 8: Installation

    TECHNICAL SPECIFICATIONS - PRO-CUT 25 (K1756-1) INPUT - SINGLE PHASE / 60 HERTZ ONLY Standard Voltage 115/230/1/50/60Hz Duty Cycle 20% on 115 V 60% on 115 V 100% on 230 V 35% on 115 V 60% on 230 V Current Range 12-25 Amps REQUIRED GAS FLOW RATE...

  • Page 9: Safety Precautions

    Read entire Installation Section before installing the PRO-CUT 25. SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK CAN KILL. • Only qualified should install this machine. • Turn the input power OFF at the disconnect switch or fuse box and discharge input capacitors inside the equipment.

  • Page 10: Gas Input Connections

    WARNING • Failure to wire as instructed may cause personal injury or damage to equipment. • To 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.

  • Page 11: Output Connections

    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 25 gas inlet WARNING...
  • Page 12 NOTES PRO-CUT 25...
  • Page 13 Section B-1 - OPERATION SECTION - Operation...Section B Safety Precautions...B-2 Description ...B-2 Preheating Temperature ...B-2 User Responsibility ...B-3 Operational Features and Controls ...B-3 Design Features and Advantages...B-3 Cutting Capability ...B-4 Consumable Life...B-4 Limitations...B-5 Controls and Settings ...B-5 Pilot Arc Discussion ... B-6 Procedure Recommendations ...B-7 General ...B-7 Suggestions for Extra Utility From the Pro-Cut System ...B-7...

  • Page 14: Operation

    Read and understand this entire section before operat- ing the machine. SAFETY PRECAUTIONS WARNING 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.

  • Page 15: Operational Features And Controls

    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.

  • Page 16: Cutting Capability

    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.

  • Page 17: Limitations

    LIMITATIONS Do not exceed output current and duty cycle rating of machine. Do not use the PRO-CUT 25 for pipe thaw- ing. CONTROLS AND SETTINGS PRESSURE REGULATOR When preparing to cut, position the machine as close to the work as possible. Make sure you have all mate- rials needed to complete the job and have taken all safety precautions.

  • Page 18: Pilot Arc Discussion

    5° - 15° Leading Angle Direction of Travel 10° - 20° Arc Lag • Use a 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.

  • Page 19: Procedure Recommendations

    PROCEDURE RECOMMENDATIONS When properly used, plasma arc cutting is a very eco- nomical process. Improper use will result in a very high operating cost. General - In All Cases • Follow safety precautions as printed throughout this operating manual and on the machine. •...
  • Page 20 NOTES PRO-CUT 25...
  • Page 21 Section C-1 Section C-1 TABLE OF CONTENTS - ACCESSORIES - Accessories...Section C Options/Accessories...C-2 PRO-CUT 25...
  • Page 22 ALWAYS USE GENUINE LINCOLN ELECTRIC ELECTRODES 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.
  • Page 23 Section D-1 Section D-1 TABLE OF CONTENTS -MAINTENANCE- Maintenance ...Section D Routine Maintenance...D-2 Periodic Maintenance ...D-2 Thermal Protection ...D-2 Replacement Of Internal Fuse...D-2 Major Component Locations ...D-3 PRO-CUT 25...

  • Page 24: Periodic Maintenance

    WARNING ELECTRIC SHOCK • 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. • Prior to Performing preventative main- tenance, perform the following capaci- tor discharge procedure to avoid elec- tric shock.
  • Page 25 FIGURE D.2 – MAJOR COMPONENT LOCATIONS 1. Central Metal Wall 2. Main Board 3. Input Board 4. Control Board 5. Fan 6. Case Wraparound 7. Torch MAINTENANCE W ER G AS M AL /115 /115 V BRA V BRA PRO-CUT 25...
  • Page 26 NOTES PRO-CUT 25...
  • Page 27 Section E-1 -THEORY OF OPERATION SECTION- Theory of Operation ...Section E General Description ...E-2 Input Line Voltage and Auxiliary Transformer ...E-2 Precharge and Protection ...E-3 Main Transformer ...E-4 Output Section and Torch...E-5 Control Board ...E-6 Protection Circuits ...E-7 Overload Protection...E-7 Thermal Protection ...E-7 Accidental Operation Protection...E-7 Safety Parts-In-Place Protection ...E-7...

  • Page 28: Theory Of Operation

    THEORY OF OPERATION 300uH 10/10W 115VAC 230V 115V Input Voltage Board 12VDC Purge Solenoid Switch 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.

  • Page 29: Precharge And Protection

    THEORY OF OPERATION FIGURE E.3 – PRECHARGE AND PROTECTION 300uH 10/10W 115VAC 230V 115V Input Voltage Board 12VDC Purge Solenoid Switch PRECHARGE AND PROTECTION The input voltage is rectified by the input rectifier on the inverter board. The resultant DC voltage is applied to the filter capacitors through the automatic reconnect of the input board.

  • Page 30: Main Transformer

    THEORY OF OPERATION 300uH 10/10W 115VAC 230V 115V Input Voltage Board 12VDC Purge Solenoid Switch MAIN TRANSFORMER 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.

  • Page 31: Output Section And Torch

    THEORY OF OPERATION FIGURE E.5 – PLASMA OUTPUT SECTION AND TORCH 300uH 10/10W 115VAC 230V 115V Input Voltage Board 12VDC Purge Solenoid Switch 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.

  • Page 32: Control Board

    THEORY OF OPERATION 300uH 10/10W 115VAC 230V 115V Input Voltage Board 12VDC Purge Solenoid Switch 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.

  • Page 33: Protection Circuits

    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.

  • Page 34: Insulated Gate Bipolar Transistor (Igbt) Operation

    THEORY OF OPERATION INSULATED GATE BIPOLAR TRANSISTOR (IGBT) OPERATION An IGBT is a type of transistor. IGBTs are semicon- ductors well suited for high frequency switching and high current applications. Drawing A shows an IGBT in a passive mode. There is no gate signal, zero volts relative to the source, and therefore, no current flow.
  • Page 35 Section F-1 TROUBLESHOOTING & REPAIR SECTION Troubleshooting & Repair Section ...Section F How to Use Troubleshooting Guide ...F-2 PC Board Troubleshooting Procedures and Replacement ...F-3 Troubleshooting Guide ...F-4 Test Procedures Input Filter Capacitor Discharge Procedure ...F-9 Main Inverter Board Resistance Test ...F-11 Input Board Voltage Test ...F-17 Main Inverter Board Voltage Test ...F-21 Torch Continuity and Solenoid Test ...F-25...

  • Page 36: Troubleshooting And 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 37 • If the PC Board uses protective shorting jumpers, don’t remove them until installation is complete. • If 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.

  • Page 38: Troubleshooting Guide

    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. POSSIBLE AREAS OF...
  • Page 39 TROUBLESHOOTING & REPAIR 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. The machine powers up properly, but only air flows when the torch trigger is pulled;...
  • Page 40 TROUBLESHOOTING & REPAIR Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) The cutting arc starts but sputters badly. The pilot arc is normal, but the arc will not transfer to the work piece. Trigger or purge is activated brief air flow then the safety light illumi- nates.
  • Page 41 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.
  • Page 42 The Thermal LED is lit after normal use. 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. POSSIBLE AREAS OF...

  • Page 43: Input Filter Capacitor Discharge Procedure

    TROUBLESHOOTING & 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.
  • Page 44 F-10 TROUBLESHOOTING & REPAIR INPUT FILTER CAPACITOR DISCHARGE PROCEDURE (continued) WARNING ELECTRIC SHOCK • 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. •...

  • Page 45: Main Inverter Board Resistance Test

    TROUBLESHOOTING & 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.
  • Page 46 F-12 TROUBLESHOOTING & REPAIR MAIN INVERTER BOARD RESISTANCE TEST (continued) LEAD 2 (NZL) LEAD 3 (EL) Plug J1 Harness Plug RIGHT SIDE OF MACHINE TEST PROCEDURE 1. Remove main input power to the PRO-CUT 2. Remove carrying handle using a 4mm allen wrench.
  • Page 47 F-13 TROUBLESHOOTING & REPAIR MAIN INVERTER BOARD RESISTANCE TEST (continued) 8. Check the IGBTs for “shorts”. Check each IGBT (6) from Gate to Collector. Normal resistance is approx- imately 100 ohms. Also check each device from Gate to Emitter. Normal resistance is approximately 40 ohms. Check each device from Emitter to Collector.
  • Page 48 F-14 TROUBLESHOOTING & REPAIR MAIN INVERTER BOARD RESISTANCE TEST (continued) 9. Check Diodes D1, D2, & 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.
  • Page 49 F-15 TROUBLESHOOTING & REPAIR MAIN INVERTER BOARD RESISTANCE TEST (continued) Remove the torch consumables. (Shield cup, Nozzle and Electrode) With the Torch Consumables removed test the output diodes. (D10 and D11) See the Wiring Diagram. LEAD 2 (NZL) LEAD 3 (EL) Plug J1 Harness...
  • Page 50 F-16 F-16 NOTES PRO-CUT 25...

  • Page 51: Input Board Voltage Test

    TROUBLESHOOTING & REPAIR INPUT 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.

  • Page 52: Test Procedures

    F-18 TROUBLESHOOTING & REPAIR INPUT BOARD VOLTAGE TEST (CONTINUED) TEST 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.
  • Page 53 F-19 TROUBLESHOOTING & REPAIR INPUT BOARD VOLTAGE TEST (CONTINUED) 10. After the relays activate check for 115VAC from both test points AC to CP. See Figure F.7. If this voltage is not present or low, the relay contacts may be defective. 11.
  • Page 54 F-20 F-20 NOTES PRO-CUT 25...

  • Page 55: Main Inverter Board Voltage Test

    TROUBLESHOOTING & 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.
  • Page 56 F-22 TROUBLESHOOTING & REPAIR MAIN INVERTER BOARD VOLTAGE TEST (CONTINUED) TEST 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.
  • Page 57 F-23 TROUBLESHOOTING & REPAIR MAIN INVERTER BOARD VOLTAGE TEST (CONTINUED) 10. Carefully test for 12VDC at test points C7. See Figure F.9. See the Wiring Diagram. This is the rectified and regulated supply for the pulse width modulation circuit. 11. Carefully test for 12VDC at C18 test points.
  • Page 58 F-24 F-24 NOTES PRO-CUT 25...

  • Page 59: Torch Continuity And Solenoid Test

    TROUBLESHOOTING & 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.
  • Page 60 F-26 TROUBLESHOOTING & REPAIR TORCH CONTINUITY AND SOLENOID TEST (continued) LEAD 2 (NZL) LEAD 3 (EL) Plug J1 EL (3) Blue Leads White & Black Pairs NZL (2) Red Leads TEST PROCEDURE 1. Remove input power to the PRO-CUT 25 machine.
  • Page 61 F-27 TROUBLESHOOTING & REPAIR TORCH CONTINUITY AND SOLENOID TEST (continued) TABLE F.1 - TORCH ASSEMBLY RESISTANCES TEST CIRCUIT(S) BEING POINTS Lead #2 To Lead #3 Lead #2 to Torch Pilot arc lead to Nozzle Lead #3 to Torch Pilot arc lead to Nozzle Pin 1 to Pin 2 Torch trigger circuit...
  • Page 62 F-28 F-28 NOTES PRO-CUT 25...

  • Page 63: Air/Gas Solenoid Test

    F-29 TROUBLESHOOTING & REPAIR 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.
  • Page 64 F-30 TROUBLESHOOTING & REPAIR AIR/GAS SOLENOID TEST (continued) LEFT SIDE OF MACHINE TEST 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.

  • Page 65: Control Board Removal And Replacement

    TROUBLESHOOTING & 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.
  • Page 66 F-32 TROUBLESHOOTING & REPAIR CONTROL BOARD REMOVAL AND REPLACEMENT (continued) FIGURE F.13 - CONTROL BOARD LOCATION Control Board 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.
  • Page 67 F-33 TROUBLESHOOTING & REPAIR CONTROL BOARD REMOVAL AND REPLACEMENT (continued) 7. A nut 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. FIGURE F.15 - CASE FRONT SCREW REMOVAL 3 Screws CAUTION...
  • Page 68 TROUBLESHOOTING & REPAIR F-34 CONTROL BOARD REMOVAL AND REPLACEMENT (continued) Replace the red PURGE button. Replace the plastic OUTPUT knob, align it in its original position, and tighten nut. Replace the red cap on the end of the OUTPUT knob. Replace the case wraparound.

  • Page 69: Input Board Removal And Replacement

    F-35 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.
  • Page 70 F-36 TROUBLESHOOTING & REPAIR INPUT BOARD REMOVAL & REPLACEMENT (continued) PROCEDURE Remove input power to PRO-CUT 25. 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.
  • Page 71 F-37 TROUBLESHOOTING & REPAIR INPUT BOARD REMOVAL & REPLACEMENT (continued) FIGURE F.17 – INPUT BOARD REMOVAL Leads Using a 7mm Nut driver, remove the four mounting nuts from the corners of the Input Board. Be careful not to lose the washer behind each nut. Input Board can be removed after these four nuts are removed.
  • Page 72 F-38 F-38 NOTES PRO-CUT 25...

  • Page 73: Main Inverter Board Removal And Replacement

    TROUBLESHOOTING & 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.
  • Page 74 TROUBLESHOOTING & REPAIR F-40 MAIN INVERTER BOARD REMOVAL & REPLACEMENT (continued) FIGURE F.18 – MAIN INVERTER BOARD REMOVAL PROCEDURE Remove input power to PRO-CUT 25. 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.
  • Page 75 TROUBLESHOOTING & REPAIR F-41 MAIN INVERTER BOARD REMOVAL & REPLACEMENT (continued) FIGURE F.19 – INVERTER BOARD LEAD LOCATIONS Harness plugs Harness Plug (J1) Reconnect all leads to the new board. Replace the four bolts and washers previously removed from the corners of the board.
  • Page 76 F-42 NOTES F-42 PRO-CUT 25...

  • Page 77: Switch Removal And Replacement

    TROUBLESHOOTING & REPAIR 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.
  • Page 78 TROUBLESHOOTING & REPAIR F-44 REMOVAL AND REPLACEMENT (continued) Switch PROCEDURE Remove input power to PRO-CUT 25. 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.

  • Page 79: Fan Removal And Replacement

    F-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.
  • Page 80 F-46 TROUBLESHOOTING & REPAIR FAN REMOVAL AND REPLACEMENT (continued) PROCEDURE Remove input power to PRO-CUT 25. 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.
  • Page 81 F-47 TROUBLESHOOTING & REPAIR FAN REMOVAL AND REPLACEMENT (continued) Using a phillips head screwdriver, remove the four mounting screws on the four corners of the fan. The fan will become free. After replacement of the fan, replace the four mounting screws located at the corners of the fan.

  • Page 82: Retest After Repair

    F-48 TROUBLESHOOTING & REPAIR Should a machine under test be rejected for any reason requiring the removal of any mechanical part that could affect the machine’s electrical characteristics, or if any electrical components are repaired or replaced, the machine must be retested. Input Volts/Hertz 230/1/60HZ Output Current Range...
  • Page 83 ELECTRICAL DIAGRAMS -ELECTRICAL DIAGRAMS SECTION- ELECTRICAL DIAGRAMS ............SECTION G WIRING DIAGRAM - PROCUT 25 .
  • Page 84 WIRING DIAGRAM - PRO-CUT 25 300uH 10/10W 115VAC 230V 115V Input Voltage Board 12VDC Purge Solenoid Switch 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. ELECTRICAL DIAGRAMS 15VAC 15VAC...

  • Page 85: Electrical Diagrams

    WIRING DIAGRAM W/ADDITIONAL INFO Typical input current draw: 115v 25A/35% = 37.7A 20A/60% = 26.7A Soft start relay 230v 25A/60% = 19A 3 to 5 sec delay 20A/100%=15A (12 vdc) Auto Reconnect Feature Listen for relay to click in after a 3 sec delay *does it work in the other input voltage 115v or 230 v ?
  • Page 86 ELECTRICAL DIAGRAMS SCHEMATIC- CONTROL PRINTED CIRCUIT BOARD - SHEET 1 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. PRO-CUT 25...

  • Page 87: Electrical Diagrams

    ELECTRICAL DIAGRAMS SCHEMATIC- CONTROL PRINTED CIRCUIT BOARD - SHEET 2 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. PRO-CUT 25...
  • Page 88 ELECTRICAL DIAGRAMS SCHEMATIC- CONTROL PRINTED CIRCUIT BOARD - SHEET 3 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. PRO-CUT 25...
  • Page 89 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 90 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 91 PC 25 TORCH DETAILS Spring is relaxed helping the push VENT AIR IS FLOWING & ELECTRODE SOL. IS “ON”. ELECTRODE SOL. ENERGIZED (surface area is great) Cup “O” rings must be good. electrode is held to the nozzle. COMPRESSED AIR INPUT Spring is compressed Air pressure pushes back...
  • Page 92 Your Company__________________________ Your Name_____________________________ Please give detailed description below: ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ SD287 04/06 Thank You, Technical Services Group Lincoln Electric Co. 22801 St. Clair Ave. Cleveland, Ohio 44117-1199 FAX 216-481-2309...

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