Lincoln Electric PRO-CUT 80 Service Manual
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Lincoln Electric PRO-CUT 80 Service Manual

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See also: Operator's Manual
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

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  • Page 1: Service Manual

    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

    (MSDS) and follow your 3.j. Also see Items 6.c. and 8. employer’s safety practices. MSDS forms are available from your welding distributor or from the manufacturer. 5.e. Also see item 1.b. PRO-CUT 80...
  • Page 4 This can create fire hazards or overheat lifting chains or Electrical Code, all local codes and the manufacturer’s cables until they fail. recommendations. 6.h. Also see item 1.c. 8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer’s recommendations. PRO-CUT 80...
  • Page 5 Toujours porter des lunettes de sécurité dans la zone de soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l’on pique le laitier. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir ttout risque d’incendie dû étincelles. PRO-CUT 80...

  • Page 6: Table Of Contents

    Accessories...........................Section C Maintenance .........................Section D Theory of Operation ......................Section E Troubleshooting and Repair....................Section F Safety Precautions ........................F-2 How to Use Troubleshooting Guide....................F-2 Troubleshooting Guide ........................F-4 Test Procedures ........................F-10 Replacement Procedures ......................F-40 Electrical Diagrams ......................Section G Parts Manual ........................P-340 Series PRO-CUT 80...
  • Page 7 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 Torch Connection .........................A-8 PRO-CUT 80...

  • Page 8: Installation

    INSTALLATION TECHNICAL SPECIFICATIONS - PRO-CUT 80 INPUT RATINGS Single Phase Input Input Currents Rated Output Amps Voltage and Hertz 208/1/60 230/1/60 460/1/60 Three Phase Input Input Currents Rated Output Amps Voltage and Hertz 208/3/60 230/3/60 460/3/60 IDLE CURRENT AND WATTS...

  • Page 9: Gas Requirements

    INSTALLATION TECHNICAL SPECIFICATIONS (Cont’d) - PRO-CUT 80 GAS REQUIREMENTS Required Gas Flow Rate Required Gas Inlet Pressure 70 PSI @ 480 SCHF 80 to 150 PSI (4.8 Bar. @ 13550 LHR) (5.4 Bar. to 10.2 Bar.) RECOMMENDED INPUT WIRE AND FUSE SIZES For all plasma cutting applications based on U.S.

  • Page 10: Safety Precautions

    A source of clean, dry air or nitrogen must be supplied ¥ If the ground clamp cannot be isolated, then keep the to the PRO-CUT 80. Oil in the air is a severe problem clamp as far as possible from other work clamp con- and must be avoided.

  • Page 11: Input Electrical Connections

    INSTALLATION INPUT CONNECTIONS GROUND CONNECTION The frame of the PRO-CUT 80 must be properly grounded. WARNING A ground terminal marked with the symbol mounted on the case bottom directly behind the input power switch for this purpose. The ground lead of the ELECTRIC SHOCK can kill.

  • Page 12: Reconnect Procedure

    3. POSITION SWITCH TO DESIRED INPUT VOLTAGE RANGE. Figure A.2. For 460: Position the large switch to 380-460. See Figure A-2. VOLTAGE = 380 - 460V 3. Move the ÒAÓ lead to the appr opriate terminal. VOLTAGE = 200 - 230V PRO-CUT 80...

  • Page 13: Gas Input Connections

    • 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. Use only a clean air supply. • Connect the gas supply to the PRO-CUT 80’s pneumatic nipple at the air filter.

  • Page 14: Output Connections

    FIGURE A.4 - TORCH CONNECTION AT CASE FRONT TORCH CONNECTION Reset Purge Status Button The PRO-CUT 80 is supplied from the factory with a Button Regulator Indicators PCT 80 cutting torch. Additional cutting torches can Gauge be ordered from the K1571 series. Hand-held and mechanized torches come with 25 or 50 foot cables.
  • Page 15 Preheat Temperature for Plasma Cutting ...................B-7 Procedure Recommendations ....................B-7 General ..........................B-7 Thin Gauge Sheet Metal ......................B-7 Thick Sections of Metal......................B-8 Suggestions for Extra Utility From the Pro-Cut System ............B-8 Machine Interface........................B-9 Arc Start............................B -9 Arc Initiated..........................B-9 Arc Voltage..........................B-9 PRO-CUT 80...

  • Page 16: Operation

    • Keep your body away from nozzle and plasma arc. • Operate the pilot arc with caution. The pilot arc is capable of burning the oper- ator, others, or even piercing safety clothing. Observe additional Safety Guidelines detailed in the beginning of this manual. PRO-CUT 80...

  • Page 17: General Description

    ¥ 3.0 second pilot arc. ordered as individual packages. ¥ Purge momentary push button. The PRO-CUT 80 initiates the plasma arc with a sim- ple, yet reliable, touch-start mechanism. This system ¥ Air regulator and pressure gauge located on the eliminates many of the failure problems associated front of machine for convenience.

  • Page 18: Cutting Capability

    0.15 in. (3.8mm). Example: 0.5 material Amps Speed (IPM) FIGURE B.1 Ð LINCOLNÕS PRO-CUT 80 MILD STEEL CUT CAP ACITY CHART Lincoln's PRO-CUT 80 Mild Steel Cut Capacity Chart 25 A 55 A...

  • Page 19: Controls And Settings

    This Regulator Control impulse can also be used to help troubleshoot a "no Knob Knob start" condition. PRO-CUT 80 Consumable Storage (behind CUTTING OPERATION door) When preparing to cut or gouge, position the machine Input as close to the work as possible.
  • Page 20 Make sure that the shield cup is hand spatter. tight. Do not use pliers or overtighten. ¥ Use the drag cup with a metal template to prevent nozzle double arcing. PRO-CUT 80...

  • Page 21: User Responsibility

    Test all procedures duplicating touching it lightly to the surface after piercing a hole. actual field conditions. Current control should be set below the mid-range. ¥ Do not allow cable or body to contact hot surface. PRO-CUT 80...
  • Page 22 WARNING ment consumables may cause damage to the torch or reduce cut quality. ELECTRIC SHOCK can kill. ¥ Turn off machine at the disconnect switch on the front of the machine before tightening, cleaning or replac- ing consumables. PRO-CUT 80...

  • Page 23: Machine Interface

    OPERATION 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 Section C-1 Section C-1 TABLE OF CONTENTS - ACCESSORIES - Accessories...........................Section C Options/Accessories........................C-2 PRO-CUT 80...

  • Page 26: Accessories

    ACCESSORIES ¥ Only Genuine Lincoln Electric consumables yield The following options/accessories are available for the best cutting performance for the PRO-CUT 80. your PRO-CUT 80 from your local Lincoln Distributor. ¥ The patent pending VORTECHª nozzle pr ovides K1681-1 Undercarriage - A valet style undercarriage an extra ÒkickÓ...
  • 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 Power Board on the right side of the machine. FIGURE D.1 Ñ LOCA TION OF INPUT FILTER CAPACITOR TERMINALS POWER BOARD CAPACITOR TERMINALS POWER RESISTOR INSULATED RIGHT SIDE OF MACHINE PLIERS INSULATED GLOVES PRO-CUT 80...

  • Page 29: Routine Maintenance

    Replace if necessary by first removing the two screws that attach the filter cage to the back 2. Filter Capacitor Conditioning (PRO-CUT 80, 400- panel assembly, then slide the cage away from the 460 VAC only) back of the machine and remove.

  • Page 30: Maintenance

    Maintenance FIGURE D.2 Ð MAJOR COMPONENT LOCA TIONS 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 Protection Circuits ........................E-7 Overload Protection......................E-7 Thermal Protection .......................E-7 Insulated Gate Bipolar Transistor (IGBT) Operation ..............E-8 Pulse Width Modulation (PWM) ....................E-9 Minimum Output........................E-9 Maximum Output........................E-9 FIGURE E.1 – PRO-CUT 80 BLOCK LOGIC DIAGRAM WORK NOZZLE ELECTRODE POWER BOARD TORCH MAIN CONNECTOR &2...

  • Page 32: Theory Of Operation

    MOTOR GENERAL DESCRIPTION INPUT LINE VOLTAGE, SWITCH AND MAIN TRANSFORMER The PRO-CUT 80 is a constant current, continuous control plasma cutting power source. The inverter The single-phase or three-phase input power is con- based power supply design is controlled by a micro- nected to the machine, via an input line cord, to a processor control board.

  • Page 33: Precharge And Protection

    The Insulated Gate Bipolar Tran- sistors supply the main transformer primary winding with DC current flow. See IGBT Operation discussion and diagrams in this section. NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion. PRO-CUT 80...

  • Page 34: Main Transformer

    If the primary currents are not equal, the control board workpiece. compensates by adjusting the IGBT gate signals. PRO-CUT 80...
  • Page 35 The air stream forces the arc out the ori- torch components: the trigger, pilot arc, cutting arc, and air fice of the nozzle. This appears as a pilot arc, which can flow systems are included. then be transferred for cutting. PRO-CUT 80...
  • Page 36 The display board receives commands from the con- machine mode and output to satisfy the requirements trol board and, via indicator lights, communicates as defined by the internal software. The control board PRO-CUT 80 status and operating conditions to the user. PRO-CUT 80...

  • Page 37: Protection Circuits

    PROTECTION CIRCUITS THERMAL PROTECTION Two thermostats protect the machine from excessive Protection circuits are designed into the PRO-CUT 80 operating temperatures. One thermostat is located on machine to sense trouble and shut down the machine the output choke and the other on the power board before the trouble damages internal machine compo- IGBT heat sink.
  • Page 38 FIGURE E.7 Ð CONTROL AND DISPLA Y BOARDS POSITIVE VOLTAGE APPLIED GATE GATE SOURCE SOURCE BODY REGION BODY REGION DRAIN DRIFT REGION DRAIN DRIFT REGION BUFFER LAYER BUFFER LAYER INJECTING LAYER INJECTING LAYER DRAIN DRAIN B. ACTIVE A. PASSIVE PRO-CUT 80...

  • Page 39: Pulse Width Modulation

    50-microsecond time The more dark area under the curve, the more power period. is present. An IGBT group consists of two IGBT modules feeding one transformer primary winding. FIGURE E.8 Ð TYPICAL IGBT OUTPUTS MINIMUM OUTPUT MAXIMUM OUTPUT PRO-CUT 80...
  • Page 40 E-10 E-10 NOTES PRO-CUT 80...

  • Page 41: How To Use Troubleshooting Guide

    Control Board Removal and Replacement ..............F-40 Display Board Removal and Replacement ..............F-43 Output Power Board Removal and Replacement............F-46 Primary Power Board and Filter Capacitor Removal and Replacement ......F-50 Input Rectifier Bridge Removal and Replacement............F-54 Retest after Repair ......................F-57 PRO-CUT 80...

  • Page 42: Troubleshooting & Repair Section

    HOW TO USE TROUBLESHOOTING GUIDE WARNING 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 you return a PC Board to The Lincoln Electric Sometimes machine failures appear to be due to PC Company for credit, it must be in the static-shielding board failures.

  • Page 44: Troubleshooting Guide

    Field Service Facility. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353. PRO-CUT 80...
  • Page 45 Replace. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353. PRO-CUT 80...
  • Page 46 70 psi (448 kPa.) CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353. PRO-CUT 80...
  • Page 47 Replace. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353. PRO-CUT 80...
  • Page 48 Replace. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353. PRO-CUT 80...
  • Page 49 Replace. blocked. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353. PRO-CUT 80...

  • Page 50: Input Filter Capacitor Discharge Procedure

    INPUT FILTER CAPACITOR DISCHARGE PROCEDURE WARNING 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 If any voltage remains, the Input Power Board. repeat this capacitor discharge procedure. FIGURE F.1 – LOCATION OF INPUT FILTER CAPACITOR TERMINALS POWER BOARD CAPACITOR TERMINALS POWER RESISTOR RIGHT SIDE OF MACHINE INSULATED PLIERS INSULATED GLOVES PRO-CUT 80...

  • Page 52: Input Rectifier Test

    INPUT RECTIFIER TEST WARNING 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 Diagram. 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. FIGURE F.2 – INPUT RECTIFIER AND LEADS #207A #207 #209 TOP VIEW PRO-CUT 80...
  • Page 54 Primary Power Board Resistance Test. Also check for leaky 8. If the input rectifier is faulty, see the Input or faulty filter capacitors. Rectifier Bridge Removal & Replacement procedure. See the Wiring Diagram and Figure F.2. PRO-CUT 80...

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

    CAPACITOR VOLTAGE TEST WARNING 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 2. Perform the Input Filter Capacitor Discharge Procedure detailed earlier in 5. Use the analog ohmmeter to perform the this section. test outlined in Table F.2. 3. Locate the primary power board and asso- ciated lead locations. See Figure F.3. PRO-CUT 80...
  • Page 57 These circuits are NOT readi- Procedure. ly tested or serviceable. NOTE: Complete power board and filter 8. Carefully reconnect leads #201, #204, #205, capacitor replacement is recom- and #208 to their appropriate terminals. mended. Torque To 75 IN. LBS. PRO-CUT 80...
  • Page 58 INPUT FILTER CAPACITOR DISCHARGE PROCEDURE BEFORE TOUCHING ANY NOTE: This test should only be conducted with MACHINE COMPONENT. the PRO-CUT 80 connected for 400 VAC or above, and with the appropriate input voltage WARNING applied. ELECTRIC SHOCK can kill.
  • Page 59 TERMINALS 460VAC 325VDC 440VAC 311VDC 415VAC 293VDC 380VAC 269VDC NOTE: If Capacitor C1 is found to be defective, both Capacitors C1 and C2 must be replaced at the same time. The capacitors must be replaced in matched sets. PRO-CUT 80...

  • Page 60: Output Power Board Resistance Test

    OUTPUT POWER BOARD RESISTANCE TEST WARNING 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 LED1 LED4 LED2 TEST POINT TEST PROCEDURE 1. Remove input power to the PRO-CUT 80 4. Carefully remove leads X4, X2, B21, X20, X40 machine. and plugs J33 and J32 from the output power board. See Figure F.4. 2. Perform...
  • Page 62 7. If the output power board “passes” the resistance test, the power diode and transistor portion of the board is good. However, other circuits on the power board may be faulty. These circuits are NOT readily tested or serviceable. PRO-CUT 80...

  • Page 63: Torch Continuity And Solenoid Test

    TORCH CONTINUITY AND SOLENOID TEST WARNING 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 FIGURE F.5 - TORCH CONNECTOR - MACHINE END TEST PROCEDURE 3. Using the ohmmeter, check the torch resis- tances per Table F.5. 1. Remove input power to the PRO-CUT 80 NOTE: Take the “Pin” test point measurements machine. at the machine end of the torch assem- 2.

  • Page 65: Air/Gas Solenoid Test

    AIR/GAS SOLENOID TEST WARNING 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 7. Install plug J31 back into the output power or very low resistance) of leads #366 and board. #361 between the solenoid and plug J31. FIGURE F.7 – PLUG J31 LOCATION G3439 PRO-CUT 80 OUTPUT (B12) (B11) TEST POINT LED3...

  • Page 67: T2 Auxiliary Transformer Test

    (T2) AUXILIARY TRANSFORMER TEST WARNING 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 3. Locate the auxiliary transformer. See Fig. F.8 appropriate leads at plugs J21 and J22. See 4. Locate and disconnect plugs J21 and J22 Figure F.8 and Table F.6.. from the wiring harness. Cut any necessary cable ties. See Figure F.8. PRO-CUT 80...
  • Page 69 9. If the auxiliary transformer tests good but it auxiliary transformer is good. does not function when connected to the PRO-CUT 80, check the harness wiring to 8. If any of the voltages are missing or very low the auxiliary transformer. See the Wiring with the proper primary voltage applied, the Diagram.

  • Page 70: Trigger Circuit Test

    TRIGGER CIRCUIT TEST WARNING 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 PROCEDURE 7. If the correct voltage is present in Step 6, carefully check for the presence of approxi- 1. Remove input power to the PRO-CUT 80 mately 15 VDC from plug J32 pin-3 machine. (lead#354) (positive) to plug J32 pin-14 (lead#312) (negative).
  • Page 72 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. Release (deactivate) the torch trigger and remove input power to the PRO-CUT 80. 10. Perform Input Filter Capacitor Discharge Procedure.
  • Page 73 F-33 F-33 TROUBLESHOOTING & REPAIR TRIGGER CIRCUIT TEST (continued) FIGURE F.10 - OUTPUT BOARD TRIGGER CIRCUIT TEST POINTS AND LEDS G3439 PRO-CUT 80 OUTPUT (B12) (B11) TEST POINT LED3 LED5 (B21) LED1 LED4 LED2 TEST POINT PRO-CUT 80 OUTPUT BOARD...
  • Page 74 F-34 F-34 TROUBLESHOOTING & REPAIR TRIGGER CIRCUIT TEST (continued) FIGURE F.11 - CONTROL BOARD LEDs PRO-CUT 55 CONTROL G3328 PRO-CUT 80 CONTROL G3443 LED2 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.

  • Page 75: Low Voltage Circuit Test

    LOW VOLTAGE CIRCUIT TEST WARNING 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 #219 18VAC 10J40 BLUE PROCEDURE 1. Remove input power to the PRO-CUT 80 5. Check for the presence of 17 VDC on the out- machine. put board. 2. Using the 5/16" nutdriver remove the case a. LED2 should be lit when 17 VDC is present.
  • Page 77 AC sup- ply voltages are being applied to the P.C. boards. See Figure F.12, Low Voltage Circuit Diagram (T2) Auxiliary Transformer Test. 11. When the test is complete, remove input power and replace the case wraparound cover. PRO-CUT 80...
  • Page 78 F-38 F-38 TROUBLESHOOTING & REPAIR LOW VOLTAGE CIRCUIT TEST (continued) FIGURE F.13 – OUTBOARD LOW VOLTAGE CIRCUIT TEST POINTS AND LEDs G3439 PRO-CUT 80 OUTPUT (B12) (B11) TEST POINT LED3 LED5 (B21) LED1 LED4 LED2 TEST POINT PRO-CUT 80 OUTPUT BOARD...
  • Page 79 F-39 F-39 TROUBLESHOOTING & REPAIR LOW VOLTAGE CIRCUIT TEST (continued) FIGURE F.14 – CONTROL BOARD LEDs PRO-CUT 80 CONTROL G3443 PRO-CUT 55 CONTROL G3328 LED2 LED1 LED3 CONTROL BOARD LED DEFINITIONS LED2: (Red) This light indicates that the +5.5 LED1: (Red) This light indicates that 18 VAC is VDC is present.

  • Page 80: Control Board Removal And Replacement

    CONTROL BOARD REMOVAL AND REPLACEMENT WARNING 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 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 3. Using the 5/16” nut driver, remove the four machine. screws holding the front assembly to the top and base of the machine.
  • Page 82 Failure to do so can result in permanent damage wraparound. to the equipment. 8. When replacing the control board, align the mounting holes with the eight mounting pins and gently slide the P.C. board onto the mounting pins until the board “snaps” onto the pins. PRO-CUT 80...

  • Page 83: Display Board Removal And Replacement

    DISPLAY BOARD REMOVAL AND REPLACEMENT WARNING 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 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 4. Carefully slide (do not force) the front away machine. from the rest of the machine about one inch.
  • Page 85 11. Inspect, clear and secure all leads in prepa- ration for the case wraparound reassembly. 7. Depress the locking tab and remove the plug 12. Using the 5/16” nut driver, install the case connector from the display board. wraparound. PRO-CUT 80...

  • Page 86: Output Power Board Removal And Replacement

    OUTPUT POWER BOARD REMOVAL AND REPLACEMENT WARNING 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 OUTPUT POWER BOARD REMOVAL & REPLACEMENT (continued) FIGURE F.21 – OUTPUT POWER BOARD REMOVAL OUTPUT POWER BOARD PROCEDURE 1. Remove input power to the PRO-CUT 80 3. Locate the output power P.C. board and machine. associated lead and plug connections. See Figures F.21 and F.22.
  • Page 88 F-48 F-48 TROUBLESHOOTING & REPAIR OUTPUT POWER BOARD REMOVAL & REPLACEMENT (continued) FIGURE F.22 – OUTPUT BOARD LEAD LOCATIONS G3439 PRO-CUT 80 OUTPUT (B12) (B11) TEST POINT LED3 LED5 (B21) LED1 LED4 LED2 TEST POINT 4. Using the 7/16” wrench, remove leads X4, X2 9.
  • Page 89 6. Replace plugs J30, J31, J32, J33, and J34. 7. Replace leads X4 and X2, then torque to 75 IN. LBS. 8. Replace lead B21 and torque it to 75 IN. LBS. 9. Clear and secure all leads and replace the wraparound cover. PRO-CUT 80...

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

    REMOVAL AND REPLACEMENT WARNING 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 FIGURE F.23 – PRIMARY POWER BOARD REMOVAL Primary Power Board With Input Filter Capacitors REMOVAL PROCEDURE 1. Remove input power from the PRO-CUT 80 4. Label the leads for reassembly. machine. 5. Remove Plug J10 and any necessary cable 2. Remove the case wraparound and perform ties.
  • Page 92 Be sure to follow the recommended static-free heat sink. methods for handling printed circuit boards. Failure to do so can result in permanent damage to the equipment. PRO-CUT 80...
  • Page 93 P.C. board and the heat sink and capacitor terminals. 5. Mount the P.C. board to the heat sink and capacitor assembly. Make sure the capacitor terminals line up with the holes in the P.C. board and with the correct capacitor polari- ties. PRO-CUT 80...

  • Page 94: Input Rectifier Bridge Removal And Replacement

    INPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT WARNING 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 TROUBLESHOOTING & REPAIR INPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued) PROCEDURE 5. With the phillips head screw driver, remove the lead terminals connected to the rectifier 1. Remove input power to the PRO-CUT 80. terminals. 2. Perform Input Filter Capacitor 6.
  • Page 96 31 in-lbs. 10. Apply Dow Corning 738 Insulating Com- pound to all six screw heads and termi- nals. The heavy input lead terminals should be against the rectifier terminals. 11. Assemble case wrap-around cover. PRO-CUT 80...

  • Page 97: Retest After Repair

    INPUT IDLE AMPS AND WATTS Input Volts/Hertz Idle Amps Idle Watts 208/230/460 0.61 Output Current Range 35 - 85 Amps Maximum Open Circuit Voltage 335 Volts PRO-CUT 80...
  • Page 98 F-58 F-58 NOTES PRO-CUT 80...
  • Page 99 DISPLAY PC BOARD ASSEMBLY ..........G-11 PRO-CUT 80...

  • Page 100: Electrical Diagrams

    L10936 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. PRO-CUT 80...
  • Page 101 WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE 3353 NUMBER. NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. PRO-CUT 80...
  • 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 1A, 400V (UNLESS OTHERWISE SPECIFIED) NUMBER. SUPPLY VOLTAGE NET POWER SUPPLY SOURCE POINT COMMON CONNECTION FRAME CONNECTION EARTH GROUND CONNECTION NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. PRO-CUT 80...
  • 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 ELECTRICAL DIAGRAMS SCHEMATIC - OUTPUT PC BOARD NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. PRO-CUT 80...
  • 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 NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE COMMON CONNECTION NUMBER. FRAME CONNECTION EARTH GROUND CONNECTION 10-31-97D 18920 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. PRO-CUT 80...
  • 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 Please include the machine’s code number and how the problem was resolved. Thank You, Technical Services Group Lincoln Electric Co. 22801 ST. Clair Ave. Cleveland, Ohio 44117-1199 FAX 216-481-2309 SVM Number ___________________________...

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