1. Manuals
  2. Brands
  3. Lincoln Electric Manuals
  4. Welding System
  5. PRO-CUT SVM146-A
  6. Service manual

Lincoln Electric PRO-CUT SVM146-A Service Manual

Lincoln electric welder user manual
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
RETURN TO MAIN INDEX
SVM146-A
September, 1999
™
PRO-CUT
80
For use with machine code numbers 10573, 10574, 10577, 10578
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

• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

Advertisement

Table of Contents
loading

Related Manuals for Lincoln Electric PRO-CUT SVM146-A

Summary of Contents for Lincoln Electric PRO-CUT SVM146-A

  • Page 1: Service Manual

    RETURN TO MAIN INDEX SVM146-A September, 1999 ™ PRO-CUT For use with machine code numbers 10573, 10574, 10577, 10578 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

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

  • Page 3: Electric Shock Can Kill

    ELECTRIC SHOCK can kill. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands.
  • Page 4 WELDING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.
  • 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 Protegez-vous contre la secousse électrique: Les circuits à...

  • Page 6: Table Of Contents

    MASTER TABLE OF CONTENTS FOR ALL SECTIONS Safety...i-iv Installation ...Section A Technical Specifications ...A-2/3 Safety Precautions...A-4 Select Suitable Location ...A-4 Stacking ...A-4 Lifting and Moving ...A-4 Tilting...A-4 High Frequency Interference Protection...A-4 Input Electrical Connections...A-5 Input Power Cord Connector Installation ...A-5 Frame Grounding ...A-5 Gas Input Connections ...A-7 Output Connections...A-8...
  • Page 7 Section A-1 - INSTALLATION SECTION - Installation Technical Specifications ...A-2 Safety Precautions...A-4 Select Suitable Location...A-4 Stacking ...A-4 Lifting and Moving ...A-4 Tilting ...A-4 High Frequency Interference Protection...A-4 Input Electrical Connections...A-5 Ground Connection ...A-5 Input Power Cord Connector Installation ...A-5 Input Wire and Fuse Size ...A-5 Reconnect Procedure...A-6 Gas Input Connections...A-7 Output Connections ...A-8...

  • Page 8: Installation

    TECHNICAL SPECIFICATIONS - PRO-CUT 80 Single Phase Input Voltage and Hertz 208/1/60 230/1/60 460/1/60 Three Phase Input Voltage and Hertz 208/3/60 230/3/60 460/3/60 IDLE CURRENT AND WATTS IDLE CURRENT AND WATTS 230/1/60 Duty Cycle 100% Current Range 35 - 85 Amps INSTALLATION INPUT RATINGS Input Currents...

  • Page 9: Technical Specifications

    TECHNICAL SPECIFICATIONS (Cont’d) - PRO-CUT 80 Required Gas Flow Rate 70 PSI @ 480 SCHF (4.8 Bar. @ 13550 LHR) RECOMMENDED INPUT WIRE AND FUSE SIZES For all plasma cutting applications based on U.S. National Electrical Code AC Input Voltage Fuse (Super Lag) Circuit Breaker 60 Hertz...

  • Page 10: Safety Precautions

    Read this entire installation section before you start installation. SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill. • Turn the input power OFF at the disconnect switch or fuse box and discharge input capacitors before working inside the equip- ment. • Do not touch electrically hot parts or electrodes with your skin or wet clothing.

  • Page 11: Input Power Cord Connector Installation

    INPUT CONNECTIONS WARNING ELECTRIC SHOCK can kill. • Have a qualified electrician install and service this equipment. • Turn the input power off at the fuse box before working on this equipment. • Do not touch electrically hot parts. Before installing the machine, check that input supply voltage, phase, and frequency are the same as the machine’s voltage, phase, and frequency as specified on the machine’s rating plate.

  • Page 12: Reconnect Procedure

    CAUTION Failure to follow these instructions can cause immedi- ate failure of components in the welder. 1. Open the access door on the side of the machine. Connection instructions are also included on the inside of the door.

  • Page 13: Gas Input Connections

    GAS INPUT CONNECTIONS Supply the PRO-CUT 80 with clean compressed air or nitrogen. • Supply pressure must be between 80 psi and 150 psi. • Flow rate should be approximately 6.0 cfm (170 I/min.). NOTE: Oil in the air supply to the PRO-CUT 80 can cause severe problems.

  • Page 14: Output Connections

    OUTPUT CONNECTIONS TORCH CONNECTION The PRO-CUT 80 is supplied from the factory with a PCT 80 cutting torch. Additional cutting torches can be ordered from the K1571 series. Hand-held and mechanized torches come with 25 or 50 foot cables. All torches are connected to the Pro-Cut with a quick connect at the case front for easy change over.
  • Page 15 Section B-1 - OPERATION SECTION - Operation...Section B Safety Instructions ...B-2 General Description ...B-3 Recommended Process and Equipment...B-3 Operational Features and Controls ...B-3 Design Features and Advantages...B-3 Cutting Capability ...B-4 Consumable Life...B-4 Limitations...B-4 Controls and Settings ...B-5 Pilot Arc Considerations ...B-5 Cutting Operation ...B-5 Safety Status Indicator ...

  • Page 16: Operation

    OPERATING INSTRUCTIONS Read and understand this entire section of operating instructions before operating the machine. SAFETY INSTRUCTIONS • Insulate yourself from the work and ground. • Always wear dry, insulating gloves. • Use ventilation or exhaust to remove fumes from breathing zone.

  • Page 17: Operation

    GENERAL DESCRIPTION The PRO-CUT 80 is an inverter based constant cur- rent, continuous control plasma cutting power source. It provides superior and reliable starting characteris- tics, cutting visibility and arc stability. When cutting expanded metal, the PRO-CUT 80 out-performs the competition due to its quick, clean response to arc transfers.

  • Page 18: Cutting Capability

    CUTTING CAPABILITY The PRO-CUT 80 is rated at 80 amps, at 60% duty cycle on a 10 minute basis or 60 amps, at 100% duty cycle. If the duty cycle is exceeded, a thermal protec- tor will shut off the output of the machine until it cools to the normal operating temperature.

  • Page 19: Controls And Settings

    CONTROLS AND SETTINGS FIGURE B.2 - CASE FRONT CONTROLS Reset Purge Status Button Button Indicators XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX Output Control Knob PRO-CUT 80 Consumable Storage (behind door) Torch Connector Work Cable OUTPUT CURRENT CONTROL KNOB - Adjusts the amount of cutting current applied.

  • Page 20: Safety Status Indicator

    - The gas will immediately turn off. gauge may show an increase in pressure after the air turns off, but this is normal. Do NOT reset the pres- sure while the air is NOT flowing. • When ready to cut, place the torch near the work, make certain all safety precautions have been taken and pull the trigger.

  • Page 21: User Responsibility

    WARNING ELECTRIC SHOCK can kill. • Turn off machine at the discon- nect switch on the front of the machine before cleaning or replacing consum- ables. - Check the conditions of the inside of the nozzle. If debris has collected, rub the electrode on the inside bottom of the nozzle to remove any oxide layer that may have built up.

  • Page 22: Thick Sections Of Metal

    THICK SECTIONS OF METAL Torch Standoff Machine Output Setting 1/8" thru 3/16" Output Setting Standoff Mid. thru Max. Range Output set above 45 Amps. • The best quality and consumable life will be obtained by holding the torch off the surface about 3/16 in.

  • Page 23: Machine Interface

    MACHINE INTERFACE The PRO-CUT 80 comes standard with a machine interface. Interface signals provided include: arc start, arc initiated, and arc voltage. These signals are acces- sible through the 14 pin MS connector on the case front. ARC START: The Arc Start circuit allows for triggering of the power source to commence cutting.
  • Page 24 B-10 B-10 NOTES PRO-CUT 80...

  • Page 25: Accessories

    Section C-1 Section C-1 TABLE OF CONTENTS - ACCESSORIES - Accessories...Section C Options/Accessories...C-2 PRO-CUT 80...
  • Page 26 ACCESSORIES ALWAYS USE GENUINE LINCOLN ELECTRIC ELECTRODES AND VORTECH™ NOZZLES • Only Genuine Lincoln Electric consumables yield the best cutting performance for the PRO-CUT 80. • The patent pending VORTECH™ nozzle provides an extra “kick” of swirl as the arc exits the nozzle, which improves cutting performance.
  • Page 27 Section D-1 Section D-1 TABLE OF CONTENTS -MAINTENANCE- Maintenance ...Section D Safety Precautions...D-2 Input Filter Capacitor Discharge Procedure ...D-2 Routine Maintenance...D-3 Periodic Maintenance ...D-3 Major Component Locations ...D-4 PRO-CUT 80...

  • Page 28: Maintenance

    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. • Prior to performing preventative maintenance, per- form the following capacitor discharge procedure to avoid electric shock.

  • Page 29: Routine Maintenance

    ROUTINE MAINTENANCE 1. Keep the cutting or gouging area and the area around the machine clean and free of combustible materials. No debris should be allowed to collect which could obstruct air flow to the machine. 2. Every 6 months or so, the machine should be cleaned with a low pressure airstream.

  • Page 30: Major Component Locations

    Maintenance FIGURE D.2 – MAJOR COMPONENT LOCATIONS 1. Case Front 2. Base and Case Back 3. Center Panel Assembly 4. Output Board Heatsink 5. Power Board Assembly 6. Case Wraparound PRO-CUT 80...
  • Page 31 Section E-1 -THEORY OF OPERATION SECTION- Theory of Operation ...Section E General Description ...E-2 Input Line Voltage, Contactor and Main Transformer...E-2 Precharge and Protection ...E-3 Main Transformer ...E-4 Output Board and Torch ...E-5 Control and Display Boards...E-6 Protection Circuits ...E-7 Overload Protection...E-7 Thermal Protection ...E-7 Insulated Gate Bipolar Transistor (IGBT) Operation ...E-8...

  • Page 32: Theory Of Operation

    THEORY OF OPERATION INPUT LINE INPUT SWITCH RECTIFIER PRESSURE SWITCH "A" SIGNAL 18/36VAC THERMOSTATS 115VAC AUXILIARY TRANSFORMER MOTOR GENERAL DESCRIPTION The PRO-CUT 80 is a constant current, continuous control plasma cutting power source. based power supply design is controlled by a micro- processor control board.

  • Page 33: Precharge And Protection

    THEORY OF OPERATION INPUT LINE INPUT SWITCH RECTIFIER PRESSURE SWITCH "A" SIGNAL 18/36VAC THERMOSTATS OUTPUT CONTROL 115VAC AUXILIARY TRANSFORMER MOTOR PRECHARGE AND PROTECTION The input voltage is rectified by the input rectifier. The resultant DC voltage is applied, through the reconnect switch, to the power board.

  • Page 34: Main Transformer

    THEORY OF OPERATION INPUT LINE INPUT SWITCH RECTIFIER PRESSURE SWITCH "A" SIGNAL 18/36VAC THERMOSTATS OUTPUT CONTROL 115VAC AUXILIARY TRANSFORMER MOTOR MAIN TRANSFORMER Each IGBT pair acts as a switch assembly. assembly feeds a separate, oppositely wound primary winding of the main transformer. The reverse direction of current flow through the main transformer primaries and the offset timing of the IGBT pairs induce an AC square wave output signal at the secondary of the...
  • Page 35 THEORY OF OPERATION FIGURE E.5 – PLASMA OUTPUT BOARD AND TORCH INPUT LINE INPUT SWITCH RECTIFIER PRESSURE SWITCH "A" 115VAC AUXILIARY TRANSFORMER MOTOR OUTPUT BOARD AND TORCH The output board contains an Insulated Gate Bipolar Transistor (IGBT) which, upon receiving a pilot signal from the control board, either enables or disables the current in the pilot winding.
  • Page 36 THEORY OF OPERATION FIGURE E.6 – CONTROL AND DISPLAY BOARDS INPUT LINE INPUT SWITCH RECTIFIER PRESSURE SWITCH "A" SIGNAL 18/36VAC THERMOSTATS OUTPUT CONTROL 115VAC AUXILIARY TRANSFORMER MOTOR CONTROL AND DISPLAY BOARDS The control board receives status and analog feed- back signals from the output board, display board, power board and various sensors.

  • Page 37: Protection Circuits

    THEORY OF OPERATION PROTECTION CIRCUITS Protection circuits are designed into the PRO-CUT 80 machine to sense trouble and shut down the machine before the trouble damages internal machine compo- nents. Both overload and thermal protection circuits are included. OVERLOAD PROTECTION The PRO-CUT 80 is electrically protected from pro- ducing higher than normal output currents.
  • Page 38 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 39: Pulse Width Modulation

    THEORY OF OPERATION PULSE WIDTH MODULATION The term PULSE WIDTH MODULATION describes how much time is devoted to conduction in the posi- tive and negative portions of the cycle. Changing the pulse width is known as MODULATION. Pulse Width Modulation (PWM) is the varying of the pulse width over the allowed range of a cycle to affect the output of the machine.
  • Page 40 E-10 E-10 NOTES PRO-CUT 80...

  • Page 41: How To Use Troubleshooting Guide

    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-10 Input Rectifier Test ...F-12 Primary Power Board Resistance Test and Capacitor Voltage Test ...F-15 Output Power Board Resistance Test...F-20 Torch Continuity and Solenoid Test ...F-23 Air/Gas Solenoid Test...F-25...

  • Page 42: 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 43 • 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 44: 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 1-800-833-9353. POSSIBLE AREAS OF...
  • Page 45 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353. detailed in the beginning of this manual.
  • Page 46 The cutting arc starts but sputters badly. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353. POSSIBLE AREAS OF...
  • Page 47 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353.
  • Page 48 The Safety LED is lit and steady. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353.
  • Page 49 The Thermal LED is lit. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353.

  • Page 50: Input Filter Capacitor Discharge Procedure

    TROUBLESHOOTING & REPAIR INPUT FILTER CAPACITOR DISCHARGE PROCEDURE Service and repair should be performed by only Lincoln Electric factory trained person- nel. Unauthorized repairs performed on this equipment may result in danger to the tech- nician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 51 F-11 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 52: Input Rectifier Test

    F-12 TROUBLESHOOTING & REPAIR Service and repair should be performed by only Lincoln Electric factory trained person- nel. Unauthorized repairs performed on this equipment may result in danger to the tech- nician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 53 F-13 TROUBLESHOOTING & REPAIR INPUT RECTIFIER TEST (continued) TEST PROCEDURE 1. Remove main input power to the machine. 2. Perform Input Discharge Procedure detailed earlier in this section. 3. Locate the input rectifier (D1) and lead loca- tions. See Figure F.2. Carefully remove the silicone sealant from leads #207, #207A, and #209.
  • Page 54 F-14 TROUBLESHOOTING & REPAIR INPUT RECTIFIER TEST (continued) TEST POINT TERMINALS +Probe 207A 207A 207A 6. If the input rectifier does not meet the accept- able readings outlined in Table F.1, the com- ponent may be faulty. Replace. NOTE: Before replacing the input rectifier (D1) check the input power switch (S1) and perform the Primary Power Board Resistance Test.

  • Page 55: Primary Power Board Resistance Test And Capacitor Voltage Test

    PRIMARY POWER BOARD RESISTANCE TEST AND CAPACITOR 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 elec-...
  • Page 56 F-16 TROUBLESHOOTING & REPAIR PRIMARY POWER BOARD RESISTANCE TEST AND CAPACITOR VOLTAGE TEST (continued) FIGURE F.3 – PRIMARY POWER BOARD REMOVAL TEST PROCEDURE 1. Remove main input power to the PRO- CUT 80. 2. Perform the Input Filter Capacitor Discharge Procedure detailed earlier in this section.
  • Page 57 F-17 TROUBLESHOOTING & REPAIR PRIMARY POWER BOARD RESISTANCE TEST AND CAPACITOR VOLTAGE TEST (continued) TEST POINT TERMINALS + Probe 207A 207A 202A 202A 203A 203A 6. If the power board does not meet the acceptable readings outlined in Table F.2, the board is faulty.
  • Page 58 F-18 TROUBLESHOOTING & REPAIR PRIMARY POWER BOARD RESISTANCE TEST AND CAPACITOR VOLTAGE TEST (continued) CAPACITOR VOLTAGE TEST This test will help the technician to determine if the input filter capacitors are being charged equally to the correct voltage levels. NOTE: This test should only be conducted with the PRO-CUT 80 connected for 400 VAC or above, and with the appropriate input voltage applied.
  • Page 59 F-19 TROUBLESHOOTING & REPAIR PRIMARY POWER BOARD RESISTANCE TEST AND CAPACITOR VOLTAGE TEST (continued) 6. Check for the appropriate voltages outlined in Table F.3. NOTE: Voltages may vary with the input line voltage. NOTE: If the capacitor voltage is too high (over 400 VDC) or too low (less than 220 VDC) the control board will deactivate relay CR1 + CR2.

  • Page 60: Output Power Board Resistance Test

    TROUBLESHOOTING & REPAIR OUTPUT POWER 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 elec-...
  • Page 61 F-21 TROUBLESHOOTING & REPAIR OUTPUT POWER BOARD RESISTANCE TEST (continued) FIGURE F.4 – OUTPUT POWER BOARD LEAD LOCATIONS (B12) (B21) TEST PROCEDURE 1. Remove input power to the PRO-CUT 80 machine. 2. Perform Input Discharge Procedure detailed earlier in this section.
  • Page 62 F-22 TROUBLESHOOTING & REPAIR OUTPUT POWER BOARD RESISTANCE TEST (continued) TABLE F.4 - OUTPUT POWER BOARD RESISTANCE TEST POINTS +Probe J33-Pin4 –Probe Terminal X2 +Probe Terminal X2 –Probe J33-Pin4 +Probe J33-Pin4 –Probe Terminal X4 +Probe Terminal X4 –Probe J33-Pin4 +Probe D29 Test Point –Probe Terminal X20 +Probe Terminal X20 –Probe D29 Test Point...

  • Page 63: 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 elec-...
  • Page 64 F-24 TROUBLESHOOTING & REPAIR TORCH CONTINUITY AND SOLENOID TEST (continued) FIGURE F.5 - TORCH CONNECTOR - MACHINE END TEST PROCEDURE 1. Remove input power to the PRO-CUT 80 machine. 2. Remove the torch assembly from the machine. TEST POINTS Pin 7 to Pin 8 Pin 7 to Torch Nozzle Pin 8 to Torch...

  • Page 65: Air/Gas Solenoid Test

    F-25 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 elec-...
  • Page 66 F-26 TROUBLESHOOTING & REPAIR AIR/GAS SOLENOID TEST (continued) TEST PROCEDURE 1. Remove input power to the machine. 2. Perform the Input Capacitor Discharge Procedure detailed earlier in this section. 3. Locate the air solenoid and leads. See Figure F.6. 4. Carefully remove plug J31 from the output power board.

  • Page 67: T2 Auxiliary Transformer Test

    TROUBLESHOOTING & REPAIR (T2) AUXILIARY TRANSFORMER 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 elec-...
  • Page 68 F-28 TROUBLESHOOTING & REPAIR (T2) AUXILIARY TRANSFORMER TEST (continued) FIGURE F.8 – T2 AUXILIARY TRANSFORMER AUXILIARY TRANSFORMER PROCEDURE 1. Remove main input power to the PRO-CUT 80 machine. 2. Perform Input Discharge Procedure detailed earlier in this section. 3. Locate the auxiliary transformer. See Fig. F.8 4.
  • Page 69 F-29 TROUBLESHOOTING & REPAIR (T2) AUXILIARY TRANSFORMER TEST (continued) TEST POINT Brown (8J21) Red (2J21) Blue (9J21) Blue (4J21) Yellow (1J21) 7. If the correct test voltages are present, the auxiliary transformer is good. 8. If any of the voltages are missing or very low with the proper primary voltage applied, the auxiliary transformer may be faulty.

  • Page 70: Trigger Circuit Test

    F-30 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 elec-...
  • Page 71 F-31 TROUBLESHOOTING & REPAIR TRIGGER CIRCUIT TEST (continued) FIGURE F.9 – SIMPLIFIED TRIGGER CIRCUIT DIAGRAM RECEPTACLE TRIGGER SWITCH IN TORCH HANDLE PROCEDURE 1. Remove input power to the PRO-CUT 80 machine. 2. Perform Input Discharge Procedure detailed earlier in this section.
  • Page 72 F-32 TROUBLESHOOTING & REPAIR TRIGGER CIRCUIT TEST (continued) 9. With the torch trigger activated check the voltage at plug J32 pin-3 (lead#354) (posi- tive) to plug J32 pin-14 (lead#312) (nega- tive). Normal is less than 1 VDC. If more than 1 VDC is indicated, the power output board may be faulty.
  • Page 73 F-33 TROUBLESHOOTING & REPAIR TRIGGER CIRCUIT TEST (continued) FIGURE F.10 - OUTPUT BOARD TRIGGER CIRCUIT TEST POINTS AND LEDS (B12) (B21) PRO-CUT 80 OUTPUT BOARD LED DEFINITIONS LED1: (Red) This light indicates that 24 VAC is being supplied to the output board from the aux- iliary transformer.
  • Page 74 F-34 TROUBLESHOOTING & REPAIR TRIGGER CIRCUIT TEST (continued) FIGURE F.11 - CONTROL BOARD LEDs LED1 LED3 CONTROL BOARD LED DEFINITIONS LED1: (Red) This light indicates that 18 VAC is being supplied to the control board from the auxiliary transformer. It also shows that the 18 VAC is being rectified and should be regulated to +15 VDC.

  • Page 75: Low Voltage Circuit Test

    TROUBLESHOOTING & REPAIR LOW VOLTAGE CIRCUIT 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 elec-...
  • Page 76 F-36 TROUBLESHOOTING & REPAIR LOW VOLTAGE CIRCUIT TEST (continued) FIGURE F.12 - LOW VOLTAGE CIRCUIT DIAGRAM T2 AUXILIARY TRANSFORMER TO H1 "C" TERMINAL INPUT RECTIFIER RECONNECT LEAD "A" PROCEDURE 1. Remove input power to the PRO-CUT 80 machine. 2. Using the 5/16" nutdriver remove the case wraparound cover.
  • Page 77 F-37 TROUBLESHOOTING & REPAIR 8. Check for the presence of +5 VDC on the control board. a. LED2 should be lit when +5 VDC is pre- sent. See Figure F.14. See Control Board LED Definitions and Figure F.12, Low Voltage Circuit Diagram. 9.
  • Page 78 F-38 TROUBLESHOOTING & REPAIR LOW VOLTAGE CIRCUIT TEST (continued) FIGURE F.13 – OUTBOARD LOW VOLTAGE CIRCUIT TEST POINTS AND LEDs (B12) (B21) PRO-CUT 80 OUTPUT BOARD LED DEFINITIONS LED1: (Red) This light indicates that 24 VAC is being supplied to the output board from the aux- iliary transformer.
  • Page 79 F-39 TROUBLESHOOTING & REPAIR LOW VOLTAGE CIRCUIT TEST (continued) FIGURE F.14 – CONTROL BOARD LEDs LED1 LED3 CONTROL BOARD LED DEFINITIONS LED1: (Red) This light indicates that 18 VAC is being supplied to the control board from the auxiliary transformer. It also shows that the 18 VAC is being rectified and should be regulated to +15 VDC.

  • Page 80: 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 elec-...
  • Page 81 F-41 TROUBLESHOOTING & REPAIR CONTROL BOARD REMOVAL AND REPLACEMENT (continued) FIGURE F.16 - CASE FRONT SCREW REMOVAL 4 Screws PROCEDURE 1. Remove input power to the PRO-CUT 80 machine. 2. Remove the wraparound cover and perform the Input Filter Discharge Procedure detailed earlier in this section.
  • Page 82 F-42 TROUBLESHOOTING & REPAIR CONTROL BOARD REMOVAL AND REPLACEMENT (continued) 5. Locate the control board and the five molex type plugs connected to it. See Figure F.17. FIGURE F.18 - CONTROL BOARD REMOVAL FROM MOUNTING PINS 7. Using the needle-nose pliers and screwdriv- er, gently remove the control board from the eight mounting pins by depressing the tabs on the mounting pins and carefully removing...

  • Page 83: Display Board Removal And Replacement

    TROUBLESHOOTING & REPAIR DISPLAY 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 elec-...
  • Page 84 F-44 TROUBLESHOOTING & REPAIR DISPLAY BOARD REMOVAL & REPLACEMENT (continued) FIGURE F.19 - CASE FRONT SCREW REMOVAL 4 Screws PROCEDURE 1. Remove the input power to the PRO-CUT 80 machine. 2. Remove the wraparound cover and perform the Input Filter Capacitor Discharge Procedure detailed earlier in this section.
  • Page 85 F-45 TROUBLESHOOTING & REPAIR DISPLAY BOARD REMOVAL & REPLACEMENT (continued) FIGURE F.20 – DISPLAY BOARD REMOVAL CASE FRONT 5. Locate the display P.C. board and the one plug connected to it. See Figure F.20. 6. Gently remove the display P.C. board from the three mounting pins.

  • Page 86: Output Power Board Removal And Replacement

    TROUBLESHOOTING & REPAIR OUTPUT POWER 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 elec-...
  • Page 87 F-47 TROUBLESHOOTING & REPAIR OUTPUT POWER BOARD REMOVAL & REPLACEMENT (continued) FIGURE F.21 – OUTPUT POWER BOARD REMOVAL PROCEDURE 1. Remove input power to the PRO-CUT 80 machine. 2. Remove the case wraparound and perform the Input Capacitor Filter Discharge Procedure detailed earlier in this section.
  • Page 88 F-48 TROUBLESHOOTING & REPAIR OUTPUT POWER BOARD REMOVAL & REPLACEMENT (continued) FIGURE F.22 – OUTPUT BOARD LEAD LOCATIONS (B12) (B21) 4. Using the 7/16” wrench, remove leads X4, X2 and B21 from the output power board. 5. Remove plugs J30, J31, J32, J33, and J34 from the output power board.
  • Page 89 F-49 TROUBLESHOOTING & REPAIR REPLACEMENT PROCEDURE 1. Apply a thin coating of Penetrox A-13 Electrical Joint Compound to the mating sur- faces of the output power board and the heat sink. Make sure the surfaces are clean. Do not allow the compound to get into the threaded holes or on the screw threads.

  • Page 90: Primary Power Board And Filter Capacitor Removal And Replacement

    PRIMARY POWER BOARD AND FILTER CAPACITOR 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 elec-...
  • Page 91 F-51 TROUBLESHOOTING & REPAIR PRIMARY POWER BOARD AND FILTER CAPACITOR REMOVAL AND REPLACEMENT (continued) FIGURE F.23 – PRIMARY POWER BOARD REMOVAL REMOVAL PROCEDURE 1. Remove input power from the PRO-CUT 80 machine. 2. Remove the case wraparound and perform the Input Filter Capacitor Discharge Procedure detailed earlier in this section.
  • Page 92 F-52 TROUBLESHOOTING & REPAIR PRIMARY POWER BOARD AND FILTER CAPACITOR REMOVAL AND REPLACEMENT (continued) FIGURE F.24 – POWER BOARD HEATSINK AND CAPACITOR REMOVAL 7. Using the Phillips Head screw driver, remove the two mounting screws from the top right of the primary power board.
  • Page 93 F-53 TROUBLESHOOTING & REPAIR PRIMARY POWER BOARD AND FILTER CAPACITOR REMOVAL AND REPLACEMENT (continued) CAPACITOR REMOVAL 1. Using the 3/8” wrench, remove the four screws holding the heat sink to the center panel assembly. Take note of the insulator placement for reassembly. The four screws have insulating washers on both sides of the panel assembly.

  • Page 94: Input Rectifier Bridge Removal And Replacement

    TROUBLESHOOTING & REPAIR INPUT RECTIFIER BRIDGE 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 elec-...
  • Page 95 F-55 TROUBLESHOOTING & REPAIR INPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued) PROCEDURE 1. Remove input power to the PRO-CUT 80. 2. Perform Input Discharge Procedure detailed earlier in this section. 3. Locate the input rectifier and the leads con- nected to it. See Figure F.25. 4.
  • Page 96 F-56 TROUBLESHOOTING & REPAIR INPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued) 7. Carefully remove the input rectifier bridge. 8. When installing a new input rectifier apply a thin coating of Penetrox A-13 Heat Sink Compound (Lincoln E2529) to the mating surfaces.

  • Page 97: Retest After Repair

    F-57 F-57 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 are repaired or replaced, the machine must be retested.
  • Page 98 F-58 F-58 NOTES PRO-CUT 80...
  • Page 99 ELECTRICAL DIAGRAMS TABLE OF CONTENTS -ELECTRICAL DIAGRAMS SECTION- ELECTRICAL DIAGRAMS ............SECTION G WIRING DIAGRAM .

  • Page 100: Electrical Diagrams

    WIRING DIAGRAM - PRO CUT 80 INPUT N.A. 3000/450 POWER MOTOR 207A S4 PRIMARY RECONNECT 207A 3000/450 XFER 1,2 TRIGGER 4 ELECTRODE 3 NOZZLE 5,6 AIR SOL 7,8 ELEC SOL SHOWN FOR 400-460VAC OPERATION 10 WORK N.C. 8 AIR SOL 2 ELEC SOL 3 TRIGGER 0.6A...
  • Page 101 SCHEMATIC - CONTROL PC BOARD +15V CUTTING CURRENT SETPOINT LOCAL TCF6000 100K 4.75K CONTROL_POT CUTTING CONTROL +5.5V TCF6000 /PURGE SHORT = TRIGGER ON OPEN = TRIGGER OFF PURGE PUSHBUTTON TRIGGER CIRCUIT +5.5V OPTOCOUPLER TCF6000 /SAFETY_RESET RESET PUSHBUTTON THERMOSTAT(S) +5.5V TCF6000 /PSI_OK PRESSURE SWITCH +5.5V...
  • Page 102 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 103 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 104 SCHEMATIC - POWER PC BOARD +15V +15V LM224 LM224 TEST D 10.0 6.2V 10.0 1.00K 1.00K 1.00K 1.00K 10.0 10.0 .0047 10.0 1000V TEST C 10.0 10.0 10.0 6.2V 10.0 1.00K 1.00K 1.00K 1.00K 10.0 .0047 1000V GATE GATE DRIVE GATE 10.0 TEST B...
  • Page 105 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 106 SCHEMATIC - OUTPUT PC BOARD 3.74K 5.11K ELECTRICAL DIAGRAMS 3.74K 3.32K 1.00K NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. 221K 1.21K 1.50K 2.00K 1.50K 221K 3.92K 1.21K 1.50K 1.50K 1.21K 221K...
  • Page 107 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 108 G-10 SCHEMATIC - DISPLAY PC BOARD 3.32K 2N4401 "READY" SIGNAL 2700p +15V 3.32K 2N4401 "AIR LOW" SIGNAL 2700p 3.32K 2N4401 "THERMAL" SIGNAL 2700p +15V 3.32K 75.0 75.0 2N4401 "SAFETY" SIGNAL 2700p +15V ELECTRICAL DIAGRAMS LED8 LED9 LED6 LED7 LED4 LED5 +15V LED3 LED2...
  • Page 109 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 110 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...

This manual is also suitable for:

Pro-cut 80

Table of Contents