Lincoln Electric PRO-CUT 55 SVM140-A manual

SVM140-A July , 2005 Safety Depends on Y ou Lincoln arc welding and cutting equipment is designed and built with safety in mind. However , your overall safety can be increased by pr oper installation . . . and thoughtful operation on your part. DO NOT INST ALL, OPERA TE OR REP AIR THIS EQUIPMENT WITHOUT READ- ING THIS MANUAL AND THE SAFETY PRECAUTI[...]

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PRO-CUT 55 i SAFETY i PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJUR Y OR DEA TH. KEEP CHILDREN AW AY . P ACEMAKER WEARERS SHOULD CONSUL T WITH THEIR DOCTOR BEFORE OPERA TING. Read and understand the following safety highlights. For additional safety inform[...]

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SAFETY ii ii PRO-CUT 55 FOR ELECTRICALL Y powered equipment. 6.a. T urn off input power using the disconnect switch at the fuse box before working on the equipment. 6.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the [...]

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES iii iii PRO-CUT 55[...]

MASTER T ABLE OF CONTENTS FOR ALL SECTIONS iv iv PRO-CUT 55 Page Safety .................................................................................................................................................i-iii Installation ..................................................................................................................[...]

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ABLE OF CONTENTS - INST ALLA TION SECTION - Section A-1 Section A-1 PRO-CUT 55 Installation T echnical Specifications ....................................................................................................... ......A-2 Safety Precautions..............[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INST ALLA TION A-2 A-2 PRO-CUT 55 TECHNICAL SPECIFICA TIONS - PRO-CUT 55 INPUT RA TINGS Single Phase Input Input Curr ents Rated Output Amps V oltage and Hertz 208/1/60 60 55 230[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INST ALLA TION A-3 A-3 PRO-CUT 55 TECHNICAL SPECIFICA TIONS (Cont’d) - PRO-CUT 55 GAS REQUIREMENTS Requir ed Gas Flow Rate Requir ed Gas Inlet Pr essur e 70 PSI @ 360 SCHF 80 t[...]

Read this entire installation section befor e you start installation. SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • T ur n the input power OFF at the disconnect switch or fuse box and dischar ge input capacitors before working inside the equip- ment. • Do not touch electrically hot parts or electrodes with your skin or wet clothing. • Always [...]

INPUT CONNECTIONS ELECTRIC SHOCK can kill. • Have a qualified electrician install and service this equipment. • T urn 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 ar e the same as the machine’ [...]

RECONNECT PROCEDURE When received dir ectly from the factory , the machines are internally connected for 230 V AC. Reconnection will be necessary if a higher input voltage is used. T o r econnect the Pr o-Cut to 460 V AC or to connect back to 230 V AC, follow the dir ections as outlined below . Follow this procedur e ONL Y while the Pro-Cut is dis-[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INST ALLA TION A-7 A-7 PRO-CUT 55 GAS INPUT CONNECTIONS Supply the Pro-Cut 55 with clean compr essed air or nitrogen. • Supply pressur e must be between 80 psi and 150 psi. •[...]

OUTPUT CONNECTIONS TORCH CONNECTION The Pro-Cut 55 is supplied fr om the factory with a PCT 80 cutting torch. Additional cutting tor ches can be order ed from the K1571 series. Hand-held and mech- anized torches come with 25 or 50 foot cables. All torches ar e connected to the Pro-Cut with a quick connect at the case front for easy change over . Se[...]

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section B-1 Section B-1 PRO-CUT 55 T ABLE OF CONTENTS - OPERA TION SECTION - Operation ............................................................................................................................... Section B Safety Instructions .....................[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC B-2 B-2 PRO-CUT 55 OPERA TING INSTRUCTIONS Read and understand this entire section of operating instructions before operating the machine. SAFETY INSTRUCTIONS ELECTRIC SHOCK can [...]

GENERAL DESCRIPTION The Pro-Cut 55 is an inverter based constant curr ent, continuous control plasma cutting power sour ce. It provides superior and r eliable starting characteristics, cutting visibility and arc stability . When cutting expanded metal, the Pro-Cut 55 out-performs the competition due to its quick, clean response to ar c transfers. T[...]

CUTTING CAP ABILITY The Pro-Cut 55 is rated at 55 amps, at 50% duty cycle on a 10 minute basis or 40 amps, at 100% duty cycle. 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 Pr o-Cut 55 when cutting mild steel. Th[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OPERA TION B-5 B-5 PRO-CUT 55 CONTROLS AND SETTINGS FIGURE B.2 - CASE FRONT CONTROLS 1. OUTPUT CURRENT CONTROL KNOB 2. TORCH CONNECTOR 3. WORK CABLE 4. INPUT POWER SWITCH 5. GAS [...]

- The gas will immediately turn off. The pr essure gauge may show an increase in pr essure after the air turns off, but this is normal. Do NOT reset the pressur e while the air is NOT flowing. • When ready to cut, place the tor ch near the work, make certain all safety precautions have been taken and pull the trigger . - The air will flow for a p[...]

ELECTRIC SHOCK can kill. • T ur n of f machine at the disconnect switch on the front of the machine before tightening, cleaning or r eplac- ing consumables. - 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. Refer to ?[...]

THICK SECTIONS OF MET AL Output set above mid-range. • The best quality and consumable life will be obtained by holding the torch of f the surface about 3/16 in. (4.7mm). T oo long an arc may compromise cut quality and consumable life. The nozzle should NOT be dragged on the work. • Use of the S22151 Drag Cup will maintain the prop- er standoff[...]

T ABLE OF CONTENTS - ACCESSORIES - Accessories ........................................................................................................................... Section C Options/Accessories...................................................................................................................C-2 Section C-1 Section C-1 PRO-CUT[...]

GENERAL OPTIONS / ACCESSORIES The following options/accessories are available for your Pro-Cut 55 fr om your local Lincoln Distributor . K1600-1 Undercarriage - A valet style under carriage with pull-out handle for machine only . Provides torch and work cable storage. S22147-043 - V ortech™ nozzle with an .043” (1.2 mm) Orifice S22147-068 - V o[...]

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section D-1 Section D-1 PRO-CUT 55 T ABLE OF CONTENTS -MAINTENANCE- Maintenance ......................................................................................................................... Section D Safety Precautions....................................[...]

ELECTRIC SHOCK can kill. • Have an electrician install and service this equipment. • T urn 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 dischar ge procedur e to avoid electric shock. INPUT FIL TER CAP [...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC MAINTENANCE D-3 D-3 PRO-CUT 55 ROUTINE MAINTENANCE 1. Keep the cutting or gouging area and the area around the machine clean and fr ee of combustible materials. No debris should [...]

1. Case Front 2. Case Back 3. Primary Power Board 4. Output Power Board Assembly 5. Control Boar d 6. Case Wrapar ound 7. Machine Base 8. Auxiliary T ransformer 9. Main T ransformer Maintenance D-4 D-4 PRO-CUT 55 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return [...]

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section E-1 Section E-1 PRO-CUT 55 Theory of Operation ............................................................................................................. Section E General Description .......................................................................[...]

GENERAL DESCRIPTION The Pro-Cut 55 is a constant curr ent, continuous con- trol plasma cutting power sour ce. The inverter based power supply design is controlled by a micr oprocessor control boar d. The control system has a safety mech- anism to insure that the nozzle and electr ode are in place before cutting or gouging. The Pr o-Cut 55 initi- at[...]

PRECHARGE AND PROTECTION The input voltage is rectified by the input r ectifier . The r esultant DC voltage is applied, thr ough the reconnect switch, to the power board. The power boar d contains prechar ging cir cuitry for the safe charging of the input filter capacitors. Once the capacitors are pr echar ged and balanced the control boar d activa[...]

THEOR Y OF OPERA TION E-4 E-4 PRO-CUT 55 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FIGURE E.4 – MAIN TRANSFORMER INPUT LINE SWITCH INPUT RECTIFIER FAN MOTORS "A" L E A D AUXILIARY TRANSFORMER OUTPUT CONTROL A[...]

OUTPUT BOARD AND TORCH The output board contains an Insulated Gate Bipolar T ransistor (IGBT) which, upon r eceiving a pilot signal from the control boar d, either enables or disables the current in the pilot winding. The cutting and pilot rectifier diodes ar e also incorporated in the output board. Ther e are two diodes for each of the secondary w[...]

CONTROL AND DISPLA Y BOARDS The control boar d receives status and analog feed- back signals from the output boar d, display board, power board and various sensors. The pr ocessor interprets these signals, makes decisions and changes machine mode and output to satisfy the requir ements as defined by the internal software. The control boar d r egula[...]

PROTECTION CIRCUITS Protection cir cuits are designed into the Pr o-Cut 55 machine to sense trouble and shut down the machine before the tr ouble damages internal machine compo- nents. Both overload and thermal protection cir cuits are included. OVERLOAD PROTECTION The Pro-Cut 55 is electrically pr otected from pr oduc- ing higher than normal outpu[...]

INSULA TED GA TE BIPOLAR TRANSISTOR (IGBT) OPERA TION An IGBT is a type of transistor . IGBT s 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 r elative to the source, and therefor e, no current flow . The drain terminal of th[...]

PULSE WIDTH MODULA TION The term PULSE WIDTH MODULA TION 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 MODULA TION. 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. MINIMU[...]

NOTES E-10 E-10 PRO-CUT 55 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section F-1 Section F-1 PRO-CUT 55 Tr oubleshooting & Repair Section ................................................................................. Section F How to Use T roubleshooting Guide ...................................................................[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC HOW TO USE TROUBLESHOOTING GUIDE Service and repair should be performed by only Lincoln Electric Factory T rained Personnel. Unauthorized repairs performed on this equipment may [...]

TROUBLESHOOTING & REP AIR F-3 F-3 PRO-CUT 55 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical conne[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-4 F-4 PRO-CUT 55 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do not un[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-5 F-5 PRO-CUT 55 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not un[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-6 F-6 PRO-CUT 55 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do not un[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-7 F-7 PRO-CUT 55 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not un[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-8 F-8 PRO-CUT 55 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do not un[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-9 F-9 PRO-CUT 55 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do not un[...]

TROUBLESHOOTING & REP AIR F-10 F-10 PRO-CUT 55 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC System is functional. If performance problems exist, see performance recommendations Replace the output board. Does arc go out [...]

NOTES F-11 F-11 PRO-CUT 55 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-12 F-12 PRO-CUT 55 INPUT FIL TER CAP ACITOR DISCHARGE PROCEDURE W ARNING Service and repair should be performed by only Lincoln Electric factory t[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-13 F-13 PRO-CUT 55 ELECTRIC SHOCK can kill. • Have an electrician install and service this equipment. • T urn the input power off at the fuse [...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-14 F-14 PRO-CUT 55 INPUT RECTIFIER TEST W ARNING Service and repair should be performed by only Lincoln Electric factory trained person- nel. Unau[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-15 F-15 PRO-CUT 55 INPUT RECTIFIER TEST (continued) TEST PROCEDURE 1. Remove main input power to the machine. 2. Perform the Input Filter Capacito[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-16 F-16 PRO-CUT 55 6. If the input r ectifier does not meet the accept- able readings outlined in T able F .1, the com- ponent may be faulty . Rep[...]

NOTES F-17 F-17 PRO-CUT 55 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-18 F-18 PRO-CUT 55 W ARNING PRIMAR Y POWER BOARD RESIST ANCE TEST AND CAP ACITOR VOL T AGE TEST Service and repair should be performed by only Lin[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-19 F-19 PRO-CUT 55 PRIMAR Y POWER BOARD RESIST ANCE TEST AND CAP ACITOR VOL T AGE TEST (continued) FIGURE F .3 – PRIMAR Y POWER BOARD REMOV AL P[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-20 F-20 PRO-CUT 55 PRIMAR Y POWER BOARD RESIST ANCE TEST AND CAP ACITOR VOL T AGE TEST (continued) TEST POINT TERMINALS ANALOG METER X10 RANGE + P[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-21 F-21 PRO-CUT 55 PRIMAR Y POWER BOARD RESIST ANCE TEST AND CAP ACITOR VOL T AGE TEST (continued) CAP ACITOR VOL T AGE TEST This test will help t[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-22 F-22 PRO-CUT 55 6. Check for the appropriate voltages outlined in T able F .3. NOTE: V oltages may vary with the input line voltage. NOTE: If t[...]

NOTES F-23 F-23 PRO-CUT 55 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-24 F-24 PRO-CUT 55 W ARNING OUTPUT POWER BOARD RESIST ANCE TEST Service and repair should be performed by only Lincoln Electric factory trained pe[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-25 F-25 PRO-CUT 55 OUTPUT POWER BOARD RESIST ANCE TEST (continued) FIGURE F .4 – OUTPUT POWER BOARD LEAD LOCA TIONS TEST PROCEDURE 1. Remove inp[...]

6. If any of the resistance checks are not corr ect, the output power board is faulty . Replace. See the Output Power Board Removal and Replacement Procedure. Note: Use D30 test point for boards G3326-2,3. 7. If the output power board “passes” the resistance test, the power diode and transistor portion of the board is good. However , other circ[...]

NOTES F-27 F-27 PRO-CUT 55 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-28 F-28 PRO-CUT 55 W ARNING TORCH CONTINUITY AND SOLENOID TEST Service and repair should be performed by only Lincoln Electric factory trained per[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-29 F-29 PRO-CUT 55 TORCH CONTINUITY AND SOLENOID TEST (continued) TEST PROCEDURE 1. Remove input power to the Pro-Cut 55 machine. 2. Remove the to[...]

TROUBLESHOOTING & REP AIR F-30 F-30 PRO-CUT 55 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TORCH CONTINUITY AND SOLENOID TEST (continued) 4. If any of the r esistance checks are not cor- r ect, the torch assembly may b[...]

NOTES F-31 F-31 PRO-CUT 55 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-32 F-32 PRO-CUT 55 W ARNING AIR/GAS SOLENOID TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unaut[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-33 F-33 PRO-CUT 55 AIR/GAS SOLENOID TEST (continued) TEST PROCEDURE 1. Remove input power to the machine. 2. Perform the Input Capacitor Discharge[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-34 F-34 PRO-CUT 55 W ARNING (T2) AUXILIAR Y TRANSFORMER TEST Service and repair should be performed by only Lincoln Electric factory trained perso[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-35 F-35 PRO-CUT 55 (T2) AUXILIAR Y TRANSFORMER TEST (continued) FIGURE F .8 – T2 AUXILIAR Y TRANSFORMER PLUG J22 PLUG J21 T2 AUXILIARY TRANSFORM[...]

7. If the correct test voltages ar e 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 . 9. If the auxiliary transformer tests good but it does not function when connected to the Pro-Cut 55, check the harness wiring to the au[...]

NOTES F-37 F-37 PRO-CUT 55 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-38 F-38 PRO-CUT 55 W ARNING TRIGGER CIRCUIT TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauth[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-39 F-39 PRO-CUT 55 TRIGGER CIRCUIT TEST (continued) FIGURE F .9 – SIMPLIFIED TRIGGER CIRCUIT DIAGRAM (Later V ersions) 9 1 #4 #2 1J31 (1J38) 2J3[...]

9. With the torch trigger activated check the voltage at plug J32 pin-3 (lead#344) (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 . Release (deactivate) the torch trigger and r emove input power to the Pro-Cut 55. 10. Perform the Input Filter [...]

TROUBLESHOOTING & REP AIR F-41 F-41 PRO-CUT 55 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TRIGGER CIRCUIT TEST (continued) G3326 PRO-CUT 55 OUTPUT LED1 C13 + LED2 D25 J32 J30 J31 LED4 LED3 LED5 LEAD#4 LEAD#2 LEAD#344 [...]

CONTROL BOARD LED DEFINITIONS LED1: (Red) This light indicates that 18 V AC is being supplied to the control boar d from the auxiliary transformer . It also shows that the 18 V AC is being rectified and should be regulated to +15 VDC. This +15 VDC supply is used to power the circuitry on the contr ol board. LED2: (Red) This light indicates that the[...]

NOTES F-43 F-43 PRO-CUT 55 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-44 F-44 PRO-CUT 55 W ARNING LOW VOL T AGE CIRCUIT TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. [...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-45 F-45 PRO-CUT 55 FIGURE F .12 - LOW VOL T AGE CIRCUIT DIAGRAM #216 #219 15J40 10J40 6J2 9J2 #61 #62 #64 1J1 2J1 4J1 #54 #51 #56 #53 4J30 1J30 6J[...]

8. Check for the presence of +5 VDC on the control boar d. 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 V oltage Circuit Diagram. 9. Check for the presence of +15 VDC being applied to the display board fr om the control board. Y ou may have to remove the display board to c[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-47 F-47 PRO-CUT 55 FIGURE F .13 – OUTBOARD LOW VOL T AGE CIRCUIT TEST POINTS AND LEDs G3326 PRO-CUT 55 OUTPUT LED1 C13 + LED2 D25 J32 J30 J31 PI[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-48 F-48 PRO-CUT 55 LOW VOL T AGE CIRCUIT TEST (continued) CONTROL BOARD LED DEFINITIONS LED1: (Red) This light indicates that 18 V AC is being sup[...]

NOTES F-49 F-49 PRO-CUT 55 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-50 F-50 PRO-CUT 55 W ARNING CONTROL BOARD REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-51 F-51 PRO-CUT 55 PROCEDURE 1. Remove input power to the Pro-Cut 55 machine. 2. Remove the wrapar ound cover and perform the Input Filter Capacit[...]

5. Locate the control boar d and the five molex type plugs connected to it. See Figure F .17. 6. Carefully remove the five molex type plugs by depressing the locking tabs and gently extracting the plugs from the P .C. board r eceptacles. 7. Using the needle-nose pliers and screwdriv- er , gently remove the contr ol board from the eight mounting pin[...]

NOTES F-53 F-53 PRO-CUT 55 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-54 F-54 PRO-CUT 55 W ARNING DISPLA Y BOARD REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory traine[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-55 F-55 PRO-CUT 55 PROCEDURE 1. Remove the input power to the Pr o-Cut 55 machine. 2. Remove the wrapar ound cover and perform the Input Filter Ca[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-56 F-56 PRO-CUT 55 FIGURE F .20 – DISPLA Y BOARD REMOV AL CASE FRONT DISPLA Y BOARD DISPLA Y BOARD REMOV AL & REPLACEMENT (continued) 5. Loc[...]

NOTES F-57 F-57 PRO-CUT 55 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

TROUBLESHOOTING & REP AIR F-58 F-58 PRO-CUT 55 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC W ARNING OUTPUT POWER BOARD REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory tr[...]

TROUBLESHOOTING & REP AIR F-59 F-59 PRO-CUT 55 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FIGURE F .21 – OUTPUT POWER BOARD REMOV AL OUTPUT POWER BOARD OUTPUT POWER BOARD REMOV AL & REPLACEMENT (continued) PROCE[...]

TROUBLESHOOTING & REP AIR F-60 F-60 PRO-CUT 55 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FIGURE F .22 – OUTPUT BOARD LEAD LOCA TIONS G3326 - [1 ] PRO-CUT 55 OUTPIUT x40 J33 J32 x20 x4 x2 B21 B1 B2 J31 J30 OUTPUT PO[...]

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 ar e clean. Do not allow the compound to get into the threaded holes or on the scr ew threads. Be sure to follow the r ecommended static-free methods for handling print[...]

TROUBLESHOOTING & REP AIR F-62 F-62 PRO-CUT 55 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC W ARNING PRIMAR Y POWER BOARD AND FIL TER CAP ACITOR REMOV AL AND REPLACEMENT Service and repair should be performed by only Li[...]

TROUBLESHOOTING & REP AIR F-63 F-63 PRO-CUT 55 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FIGURE F .23 – PRIMAR Y POWER BOARD REMOV AL PRIMARY POWER BOARD WITH INPUT FIL TER CAP ACITORS PRIMAR Y POWER BOARD AND FIL [...]

TROUBLESHOOTING & REP AIR F-64 F-64 PRO-CUT 55 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FIGURE F .24 – POWER BOARD HEA TSINK AND CAP ACITOR REMOV AL CAP ACITOR CLAMP 3/8" MOUNTING INSULA TOR (2) MOUNTING SCRE[...]

CAP ACITOR REMOV AL 1. Using the 3/8” wrench, r emove the four screws holding the heat sink assembly to the upper and bottom sections of the machine. See Figure F .24. 2. Remove the gas hose restraints fr om the bot- tom of the heat sink assembly . 3. Remove the two thermostat leads from the thermostat, which is located next to the upper capacito[...]

TROUBLESHOOTING & REP AIR F-66 F-66 PRO-CUT 55 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC W ARNING INPUT RECTIFIER BRIDGE REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factor[...]

TROUBLESHOOTING & REP AIR F-67 F-67 PRO-CUT 55 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FIGURE F .25 – INPUT RECTIFIER LEAD LOCA TIONS #207 #207A #209 A B C CAP HEAD MOUNTING SCREW INPUT RECTIFIER BRIDGE REMOV AL [...]

TROUBLESHOOTING & REP AIR F-68 F-68 PRO-CUT 55 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INPUT RECTIFIER BRIDGE REMOV AL AND REPLACEMENT (continued) 7. Carefully r emove the input rectifier bridge. 8. When installing[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-69 F-69 PRO-CUT 55 RETEST AFTER REP AIR Should a machine under test be rejected for any r eason requiring the r emoval of any mechanical part that[...]

NOTES F-70 F-70 PRO-CUT 55 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

ELECTRICAL DIAGRAMS G-1 G-1 PRO CUT 55 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Electrical Diagrams Section ..........................................................................................Section G Wiring Diagram (208V , 230V , 460V) (L10634) ......................................................[...]

ELECTRICAL DIAGRAMS G-2 PROCUT 55 WIRING DIAGRAM - ENTIRE MACHINE WI R I NG DIAGRAM P RO-CUT 5 5 ELECTRICAL SYMBOLS PER E15 37 12 34 CONNECTOR CAVITY NUMBERING SEQUENCE (VIEWED FROM COMPONENT SIDE OF BOARD) NOTES: COLOR CODE: R = RED FOR THREE PHASE INPUT: CONNECT GREEN LEAD TO GROU ND PER NATIONAL ELECTRIC CODE. CONNECT BLACK, RED & WHITE LEAD[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-3 PROCUT 55 SCHEMA TIC - PLASMA OUTPUT BOARD G-3 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual.[...]

ELECTRICAL DIAGRAMS G-4 PROCUT 55 SCHEMA TIC-POWER PC BOARD G-4 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-5 PROCUT 55 PC BOARD ASSEMBL Y-DISPLA Y CAD Ch'ge. Sht. No. NO. DR. SCALE DATE CHK. SUBJECT SHT. EQUIP. SUP'S'D'G. CLEVELAND, OHIO U. S.[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-6 PROCUT 55 SCHEMA TIC - DISPLA Y PC BOARD G-6 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual.[...]

ELECTRICAL DIAGRAMS G-7 PROCUT 55 SCHEMA TIC - CONTROL PC BOARD G-7 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty . Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro- vided for reference only . Lincoln Electric discourages board level troub[...]

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty . Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro- vided for reference only . Lincoln Electric discourages board level troub[...]

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty . Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro- vided for reference only . Lincoln Electric discourages board level troub[...]

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty . Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro- vided for reference only . Lincoln Electric discourages board level troub[...]

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty . Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro- vided for reference only . Lincoln Electric discourages board level troub[...]

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty . Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro- vided for reference only . Lincoln Electric discourages board level troub[...]

SVM ERROR REPORTING FORM We need to know if there are errors in our manuals. We also value any suggestions as to additional tests or procedures that would make this SVM a better tool for you. If you discover new or different “Problems or Symptoms” that are not covered in the three col- umn troubleshooting chart, please share this information wi[...]