Lincoln Electric SVM146-A manual

SVM146-A September , 1999 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 PRE[...]

Retur n to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SAFETY i i PR O-CUT 80 FOR ENGINE po wered equipment. 1.a. T ur n the engine off bef ore troubleshooting and maintenance wor k unless the maintenance work requires it to be running. ____________________________________________________ 1.b . Oper ate engines in open[...]

Retur n to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SAFETY ii ii PR O-CUT 80 ARC RA YS can b urn. 4.a. Use a shield with the proper filter and cov er plates to protect your e yes from sparks and the ra ys of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I [...]

Retur n to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SAFETY iii iii PR O-CUT 80 FOR ELECTRICALL Y po wered equipment. 8.a. T ur n off input power using the disconnect switch at the fuse bo x before working on the equipment. 8.b . Install equipment in accordance with the U.S. National Electrical Code, all local codes [...]

Retur n to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SAFETY iv iv PR O-CUT 80 PRÉCAUTIONS DE SÛRETÉ Pour votre pr opre protection lir e 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:[...]

MASTER T ABLE OF CONTENTS FOR ALL SECTIONS v v PR O-CUT 80 Page Safety ............................................................................................................................... ..................i-iv Installation ...................................................................................................................[...]

Retur n 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 PR O-CUT 80 Installation T echnical Specifications .............................................................................................................A-2 Safety Precautions.............[...]

Retur n 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 PR O-CUT 80 TECHNICAL SPECIFICA TIONS - PRO-CUT 80 INPUT RA TINGS Single Phase Input Input Currents Rated Output Amps V oltage and Hertz 208/1/60 87 80 23[...]

Retur n 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 PR O-CUT 80 TECHNICAL SPECIFICA TIONS (Cont’d) - PRO-CUT 80 GAS REQUIREMENTS Requir ed Gas Flow Rate Required Gas Inlet Pr essure 70 PSI @ 480 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 befor e 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 ur n the input power of f at the fuse box befor e working on this equipment. • Do not touch electrically hot parts. Befor e 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 ar e 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 VAC or to connect back to 230 V AC, follow the directions as outlined below . Follow this procedur e ONL Y while the Pro-Cut is dis- [...]

Retur n 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 PR O-CUT 80 GAS INPUT CONNECTIONS Supply the PRO-CUT 80 with clean compressed air or nitrogen. • Supply pr essure must be between 80 psi and 150 psi. ?[...]

XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX PRO-CUT 80 T orch Connector W ork Cable Input P ower Switch Output Control Knob Consumable Storage (behind door) Status Indicators Reset Button Gas Purge Button Gas Regulator Gauge Gas Regulator Knob Interface Connector OUTPUT CONNECTIONS TORCH CONNECTION The PRO-CUT 80 is supplied from the factory with a PCT[...]

Retur n to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section B-1 Section B-1 PR O-CUT 80 T ABLE OF CONTENTS - OPERA TION SECTION - Operation ............................................................................................................................... Section B Safety Instructions ...................[...]

Retur n 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 PR O-CUT 80 OPERA TING INSTRUCTIONS Read and understand this entire section of operating instructions before operating the machine. SAFETY INSTRUCTIONS ELECTRIC SHOCK ca[...]

GENERAL DESCRIPTION The PRO-CUT 80 is an inverter based constant cur- r ent, continuous contr ol plasma cutting power source. It provides superior and r eliable 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 ar c transfer[...]

CUTTING CAP ABILITY 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. Figur e B.1 shows the cut capacity of the PRO-CUT 80 when cutting mild steel. [...]

Retur n 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 PR O-CUT 80 CONTROLS AND SETTINGS FIGURE B.2 - CASE FRONT CONTROLS OUTPUT CURRENT CONTROL KNOB - Adjusts the amount of cutting current applied. Af fects cutti[...]

- The gas will immediately turn off. The pressur e gauge may show an increase in pr essure after the air tur ns off, but this is normal. Do NOT r eset the pres- sur e while the air is NOT flowing. • When r eady to cut, place the torch near the work, make certain all safety precautions have been taken and pull the trigger . - The air will flow for[...]

ELECTRIC SHOCK can kill. • T ur n of f machine at the discon- nect switch on the front of the machine before tightening, 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. Refer to ?[...]

THICK SECTIONS OF MET AL Output set above 45 Amps. • 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 compr omise cut quality and consumable life. The nozzle should NOT be dragged on the work. • Use of the S22151 Drag Cup will maintain the pr op- er standoff[...]

MA CHINE INTERF A CE The PRO-CUT 80 comes standard with a machine interf ace. Interf ace signals provided include: arc star t, arc initiated, and arc v oltage. These signals are acces- sib le through the 14 pin MS connector on the case front. ARC ST ART : The Arc Star t circuit allo ws for triggering of the power source to commence cutting. This ci[...]

NOTES B-10 B-10 PR O-CUT 80 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[...]

T ABLE OF CONTENTS - ACCESSORIES - Accessories ........................................................................................................................... Section C Options/Accessories...................................................................................................................C-2 Section C-1 Section C-1 PR O-CU[...]

GENERAL OPTIONS / ACCESSORIES The following options/accessories are available for your PRO-CUT 80 from your local Lincoln Distributor . K1681-1 Undercarriage - A valet style under carriage with pull-out handle for machine only . Pr ovides torch and work cable storage. S22147-043 - V ortech™ nozzle with an .043” (1.2 mm) Orifice (For 35 - 60 Amp[...]

Retur n to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section D-1 Section D-1 PR O-CUT 80 T ABLE OF CONTENTS -MAINTENANCE- Maintenance ......................................................................................................................... Section D Safety Precautions..................................[...]

ELECTRIC SHOCK can kill. • Have an electrician install and service this equipment. • T ur n the input power of f at the fuse box befor e working on equipment. • Do not touch electrically hot parts. • Prior to performing pr eventative maintenance, per- form the following capacitor dischar ge procedur e to avoid electric shock. INPUT FIL TER [...]

Retur n 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 PR O-CUT 80 ROUTINE MAINTENANCE 1. Keep the cutting or gouging ar ea and the area ar ound the machine clean and fr ee of combustible materials. No debris sho[...]

6 4 3 5 1 2 Maintenance D-4 D-4 PR O-CUT 80 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 D .2 – MAJOR COMPONENT LOCA TIONS 1. Case Front 2. Base and Case Back 3. Center P anel Assembly 4. Output Boar d Heatsink 5. [...]

Retur n to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section E-1 Section E-1 PR O-CUT 80 Theory of Operation ............................................................................................................. Section E General Description .....................................................................[...]

GENERAL DESCRIPTION The PRO-CUT 80 is a constant current, continuous contr ol plasma cutting power sour ce. The inverter based power supply design is controlled by a micr o- pr ocessor contr ol board. The control system has a safety mechanism to insure that the nozzle and elec - tr ode ar e in place before cutting or gouging. The PRO- CUT 80 initia[...]

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 circuitry for the safe char ging of the input filter capacitors. Once the capacitors are pr echarged and balanced the control boar d activat[...]

THEOR Y OF OPERA TION E-4 E-4 PR O-CUT 80 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 MOTOR "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 board, either enables or disables the current in the pilot winding. The cutting and pilot rectifier diodes are also incorporated in the output board. There are two diodes for the pilot winding and four[...]

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 interpr ets 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 egul[...]

PROTECTION CIRCUITS Pr otection cir cuits are designed into the PRO-CUT 80 machine to sense trouble and shut down the machine befor e the tr ouble damages inter nal machine compo- nents. Both overload and thermal protection cir cuits ar e included. OVERLOAD PROTECTION The PRO-CUT 80 is electrically protected fr om pro- ducing higher than normal out[...]

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 PR O-CUT 80 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[...]

Retur n to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section F-1 Section F-1 PR O-CUT 80 T roubleshooting & Repair Section ................................................................................. Section F How to Use T roubleshooting Guide .................................................................[...]

Retur n 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[...]

ELECTRIC SHOCK can kill. Have an electrician install and service this equipment. T ur n the machine OFF befor e working on equipment. Do not touch electrically hot parts. Sometimes machine failures appear to be due to PC boar d failur es. These problems can sometimes be traced to poor electrical connections. T o avoid pr ob- lems when troubleshooti[...]

Retur n 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 PR O-CUT 80 Obser ve Saf ety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do no[...]

Retur n 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 PR O-CUT 80 TROUBLESHOOTING GUIDE Obser v e Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do no[...]

Retur n 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 PR O-CUT 80 Obser ve Saf ety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do no[...]

Retur n 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 PR O-CUT 80 TROUBLESHOOTING GUIDE Obser v e Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do no[...]

Retur n 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 PR O-CUT 80 Obser ve Saf ety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do no[...]

Retur n 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 PR O-CUT 80 Obser ve Saf ety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do no[...]

Retur n 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-10 F-10 PR O-CUT 80 INPUT FIL TER CAP ACITOR DISCHARGE PROCEDURE W ARNING Service and repair should be performed by only Lincoln Electric factory[...]

Retur n 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-11 F-11 PR O-CUT 80 ELECTRIC SHOCK can kill. • Have an electrician install and service this equipment. • T ur n the input power of f at the f[...]

Retur n 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 PR O-CUT 80 INPUT RECTIFIER TEST W ARNING Service and repair should be performed by only Lincoln Electric factory trained person - nel. U[...]

Retur n 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 PR O-CUT 80 INPUT RECTIFIER TEST (continued) TEST PROCEDURE 1. Remove main input power to the machine. 2. Perform the Input Filter Capaci[...]

TEST POINT TERMINALS ANALOG METER X10 RANGE +Pr obe - Probe Acceptable Meter Readings Retur n 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 PR O-CUT 80 6. If the input rectifier does not meet[...]

PRIMAR Y POWER BOARD RESIST ANCE TEST AND CAP ACITOR VOL T AGE TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid elec- tri[...]

Retur n 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 PR O-CUT 80 PRIMAR Y POWER BOARD RESIST ANCE TEST AND CAP ACITOR VOL T AGE TEST (continued) FIGURE F .3 – PRIMAR Y POWER BOARD REMOV AL[...]

Retur n 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-17 F-17 PR O-CUT 80 PRIMAR Y POWER BOARD RESIST ANCE TEST AND CAP ACITOR VOL T AGE TEST (continued) TEST POINT TERMINALS ANALOG METER X10 RANGE +[...]

Retur n 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 PR O-CUT 80 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[...]

Retur n 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 PR O-CUT 80 6. Check for the appr opriate voltages outlined in T able F .3. NOTE: V oltages may vary with the input line voltage. NOTE: I[...]

OUTPUT POWER BOARD RESIST ANCE TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid elec- trical shock, please observe all sa[...]

Retur n 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 PR O-CUT 80 OUTPUT POWER BOARD RESIST ANCE TEST (continued) FIGURE F .4 – OUTPUT POWER BOARD LEAD LOCA TIONS TEST PROCEDURE 1. Remove i[...]

6. If any of the r esistance checks are not corr ect, the output power board is faulty . Replace. See the Output Power Board Removal and Replacement Procedure. 7. If the output power boar d “passes” the resistance test, the power diode and transistor portion of the boar d is good. However , other circuits on the power board may be faulty . Thes[...]

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 r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid elec- trical shock, please observe all saf[...]

Retur n 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 PR O-CUT 80 TORCH CONTINUITY AND SOLENOID TEST (continued) TEST PROCEDURE 1. Remove input power to the PRO-CUT 80 machine. 2. Remove the [...]

AIR/GAS SOLENOID TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid elec- trical shock, please observe all safety notes and[...]

Retur n 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-26 F-26 PR O-CUT 80 AIR/GAS SOLENOID TEST (continued) TEST PROCEDURE 1. Remove input power to the machine. 2. Perform the Input Capacitor Dischar[...]

(T2) AUXILIAR Y TRANSFORMER TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid elec- trical shock, please observe all safet[...]

Retur n 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 PR O-CUT 80 (T2) AUXILIAR Y TRANSFORMER TEST (continued) FIGURE F .8 – T2 AUXILIAR Y TRANSFORMER PROCEDURE 1. Remove main input power t[...]

7. If the corr ect test voltages are pr esent, 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 80, check the harness wiring to the a[...]

TRIGGER CIRCUIT TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid elec- trical shock, please observe all safety notes and [...]

Retur n 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-31 F-31 PR O-CUT 80 TRIGGER CIRCUIT TEST (continued) FIGURE F .9 – SIMPLIFIED TRIGGER CIRCUIT DIAGRAM 9 1 #4 #2 1J31 2J31 +17VDC 3J32 #344 TORC[...]

9. With the tor ch 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 boar d may be faulty . Release (deactivate) the torch trigger and r emove input power to the PRO-CUT 80. 10. Perform the Input Filte[...]

TROUBLESHOOTING & REP AIR F-33 F-33 PR O-CUT 80 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) G3439 PRO-CUT 80 OUTPUT LED1 LED2 D29 LED4 LED3 LED5 J33 J31 J34 J32 J30 X20 X40 X4 X2 (B12) [...]

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 r egulated to +15 VDC. This +15 VDC supply is used to power the circuitry on the contr ol boar d. LED2: (Red) This light indicates that t[...]

LOW VOL T AGE CIRCUIT TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid elec- trical shock, please observe all safety note[...]

Retur n 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-36 F-36 PR O-CUT 80 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 [...]

8. Check for the pr esence of +5 VDC on the contr ol boar d. a. LED2 should be lit when +5 VDC is pr e- sent. See Figure F .14. See Control Board LED Definitions and Figure F .12, Low V oltage Circuit Diagram. 9. Check for the pr esence of +15 VDC being applied to the display board fr om the control boar d. Y ou may have to remove the display boar [...]

Retur n 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 PR O-CUT 80 FIGURE F .13 – OUTBOARD LOW VOL T AGE CIRCUIT TEST POINTS AND LEDs G3439 PRO-CUT 80 OUTPUT LED1 LED2 D29 LED4 LED3 LED5 J33[...]

Retur n 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 PR O-CUT 80 LOW VOL T AGE CIRCUIT TEST (continued) CONTROL BOARD LED DEFINITIONS LED1: (Red) This light indicates that 18 V AC is being s[...]

CONTROL BOARD REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid elec- trical shock, please observe all[...]

Retur n 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-41 F-41 PR O-CUT 80 PROCEDURE 1. Remove input power to the PRO-CUT 80 machine. 2. Remove the wrapar ound cover and perform the Input Filter Disch[...]

5. Locate the contr ol board and the five molex type plugs connected to it. See Figure F .17. 6. Car efully remove the five molex type plugs by depr essing the locking tabs and gently extracting the plugs from the P .C. board receptacles. 7. Using the needle-nose pliers and scr ewdriv- er , gently remove the control boar d from the eight mounting p[...]

DISPLA Y BOARD REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid elec- trical shock, please observe al[...]

Retur n 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 PR O-CUT 80 PROCEDURE 1. Remove the input power to the PRO-CUT 80 machine. 2. Remove the wrapar ound cover and perform the Input Filter C[...]

5. Locate the display P .C. board and the one plug connected to it. See Figure F .20. 6. Gently r emove the display P .C. board from the three mounting pins. Be sure to follow the r ecommended static-free methods for handling printed circuit boar ds. Failur e to do so can r esult in permanent damage to the equipment. 7. Depr ess the locking tab and[...]

OUTPUT POWER BOARD REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid elec- trical shock, please observ[...]

TROUBLESHOOTING & REP AIR F-47 F-47 PR O-CUT 80 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 REMOV AL & REPLACEMENT (continued) PROCEDURE 1. Remove inp[...]

TROUBLESHOOTING & REP AIR F-48 F-48 PR O-CUT 80 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 G3439 PRO-CUT 80 OUTPUT LED1 LED2 D29 LED4 LED3 LED5 J33 J31 J34 J32 J30 X20 X40[...]

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 thr eaded holes or on the scr ew threads. Be sure to follow the r ecommended static-free methods for handling prin[...]

PRIMAR Y POWER BOARD AND FIL TER CAP ACITOR REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid elec- tr[...]

TROUBLESHOOTING & REP AIR F-51 F-51 PR O-CUT 80 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 PRIMAR Y POWER BOARD AND FIL TER CAP ACITOR REMOV AL AND REPLACEMENT (continued[...]

TROUBLESHOOTING & REP AIR F-52 F-52 PR O-CUT 80 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 PRIMAR Y POWER BOARD AND FIL TER CAP ACITOR REMOV AL AND REPLAC[...]

CAP ACITOR REMOV AL 1. Using the 3/8” wr ench, remove the four scr ews holding the heat sink to the center panel assembly . T ake note of the insulator placement for reassembly . The four scr ews have insulating washers on both sides of the panel assembly . These must be pr operly r eplaced upon r eassembly . 2. Car efully push the heat sink in t[...]

INPUT RECTIFIER BRIDGE REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid elec- trical shock, please ob[...]

TROUBLESHOOTING & REP AIR F-55 F-55 PR O-CUT 80 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 #207A #207 #209 A B C INPUT RECTIFIER BRIDGE REMOV AL AND REPLACEMENT (contin[...]

TROUBLESHOOTING & REP AIR F-56 F-56 PR O-CUT 80 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. Car efully remove the input r ectifier bridge. 8. When installi[...]

Retur n 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-57 F-57 PR O-CUT 80 RETEST AFTER REP AIR Should a machine under test be rejected for any r eason requiring the removal of any mechanical part tha[...]

NOTES F-58 F-58 PR O-CUT 80 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[...]

G-1 ELECTRICAL DIA GRAMS G-1 PR O-CUT 80 T ABLE OF CONTENTS -ELECTRICAL DIA GRAMS SECTION- ELECTRICAL DIA GRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION G WIRING DIA GRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

ELECTRICAL DIA GRAMS G-2 PRO-CUT 80 WIRING DIA GRAM - PRO CUT 80 1 ++VOLT 6 RELAY 12 GND 11 TRIGGER 3 IGBT 2,6 PSI SWITCH 10 ELEC SOL 9 AIR SOL 214 7 210 275 J22 1 216 8 A H4 TP2 18V FRONT OF MACHINE 3 8 MAIN P_XFMR 7 XFMR 202 10 PSI SET ELEC XFER 1 1,2 TRIGGER + 204 4 ELECTRODE 204 208 TRANSFORMER 61 I 64 W 401 J10 P_XFMR 9 2 354 3 5 8 X2 312 7 J3[...]

ELECTRICAL DIA GRAMS G-3 PRO-CUT 80 SCHEMA TIC - CONTROL PC BO ARD LT1014 LT1014 TCF6000 ELECTRODE SHUNT GAIN = 80.0 1V = 12.50 A TCF6000 1V = 68.07mA LM224 X16 5 10.0K R94 COM SHUNT 1.00K R88 1.0A 30V D21 BOARD OUTPUT J3 5 C53 V V INPUT CC EE NC OUT INPUT NULL 4 NULL 7 OP27 X6 3 8 2 6 5 1 C47 7.68K R73 S18395-13 ASSY 1.30K R177 LED2 475 R176 D9 3.[...]

NO TE: Lincoln Electric assumes no responsibility for liab lilities resulting from board le vel troub leshooting. PC Board repairs will invalidate y our factory warranty . Individual Printed Circuit Board Components are not a vailable fr om Lincoln Electric. This information is pro- vided for ref erence only . Lincoln Electr ic discourages board le[...]

NO TE: Lincoln Electric assumes no responsibility for liab lilities resulting from board le vel troub leshooting. PC Board repairs will invalidate y our factory warranty . Individual Printed Circuit Board Components are not a vailable fr om Lincoln Electric. This information is pro- vided for ref erence only . Lincoln Electr ic discourages board le[...]

ELECTRICAL DIA GRAMS G-6 PRO-CUT 80 SCHEMA TIC - PO WER PC BO ARD C3 C1 E2 E4 C2 E3 G2 C4 E1 A2 G4 G3 G1 CAPACITOR A1 A1 C1 A1 A2 C1 208 PRIMARY (VOLTAGE PROTECTION) 1.00K R97 221K R44 TRANSFORMER PRIMARY 325VDC (NOMINAL) TRANSFORMER 205 B205 B208 1000V .22 C27 2000V .022 C22 2000V .022 C4 +15V 1000V .22 C26 1A 1000V D2 2000V .022 C1 1A 1000V D1 J1[...]

NO TE: Lincoln Electric assumes no responsibility for liab lilities resulting from board le vel troub leshooting. PC Board repairs will invalidate y our factory warranty . Individual Printed Circuit Board Components are not a vailable fr om Lincoln Electric. This information is pro- vided for ref erence only . Lincoln Electr ic discourages board le[...]

ELECTRICAL DIA GRAMS G-8 PRO-CUT 80 SCHEMA TIC - OUTPUT PC BO ARD OCI1 Vcc GND HP2201 5 8 NOZZLE CHASSIS ELECTRODE J32 10 400V .1 C33 15W 1.5K R51 A1 C A T12705-56 5 6 B12 15W 1.5K R53 15W 1.5K R66 C34 15W 1.5K R52 15W 1.5K R50 15W 1.5K R65 A1 C A T12705-56 1 2 3000V .0047 C37 3000V .0047 C30 180J 480V TP3 180J 480V TP2 2000V .0015 C3 D28 3A 1000V [...]

NO TE: Lincoln Electric assumes no responsibility for liab lilities resulting from board le vel troub leshooting. PC Board repairs will invalidate y our factory warranty . Individual Printed Circuit Board Components are not a vailable fr om Lincoln Electric. This information is pro- vided for ref erence only . Lincoln Electr ic discourages board le[...]

ELECTRICAL DIA GRAMS G-10 PRO-CUT 80 SCHEMA TIC - DISPLA Y PC BO ARD LED4 5 6 1 2 J40 3 LED5 7 8 J40 12 3 4 8 7 LED3 7 8 5 6 J40 4 1 2 4 3 100 R12 50V 2700p C3 6.81K R10 3.32K R9 J40 8 J40 9 Q3 2N4401 100 R11 COM +15V +15V +15V COM COM COM +15V +15V +15V HLMP-2755 HLMP-2450 LAST NO. USED SUPPLY VOLTAGE NET C- 9 LED- LABELS 5 20 3 2 1 4 5 J40 15 10 [...]

NO TE: Lincoln Electric assumes no responsibility for liab lilities resulting from board le vel troub leshooting. PC Board repairs will invalidate y our factory warranty . Individual Printed Circuit Board Components are not a vailable fr om Lincoln Electric. This information is pro- vided for ref erence only . Lincoln Electr ic discourages board le[...]

SVM ERR OR REPORTING FORM W e need to know if there are errors in our manuals. W e also v alue any suggestions as to additional tests or procedures that would mak e this SVM a better tool f or y ou. If you disco ver ne w or diff erent “Prob lems or Symptoms” that are not cov ered in the three col- umn troubleshooting char t, please share this i[...]