Lincoln Electric SVM149-A manual

SVM149-A October , 2006 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 PRECA[...]

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 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 information it is strongly r[...]

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 4.c. When not cutting or gouging, make certain no part of the elec- trode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard. 4.d. Do not cut or gouge tanks, drums or containers until the proper steps have been [...]

SAFETY iii iii Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pou[...]

MASTER T ABLE OF CONTENTS FOR ALL SECTIONS iv iv PRO-CUT 25 Page Safety .................................................................................................................................................i-iii Installation ..................................................................................................................[...]

PRO-CUT 25 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES[...]

T ABLE OF CONTENTS - INST ALLA TION SECTION - Section A-1 Section A-1 PRO-CUT 25 Installation T echnical Specifications ....................................................................................................... ......A-2 Safety Precautions..................................................................................................[...]

INST ALLA TION A-2 A-2 PRO-CUT 25 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 eight Including T orch Cable 35 lbs. 15.9 kg. INPUT - SINGLE PHASE / 60 HERTZ ONL Y RA TED OUTPUT OUTPUT RECOMMEND INPUT WIRE AND FUSE SIZES R[...]

INST ALLA TION A-3 A-3 PRO-CUT 25 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 Read entire Installation Section before installing the PRO-CUT 25. SAFETY PRECAUTIONS ELECTRIC SHOCK CAN KILL. • Only qualified personnel shou[...]

INST ALLA TION A-4 A-4 PRO-CUT 25 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 • Failure to wire as instructed may cause personal injury or damage to equipment. • T o be installed or checked by an electrician or qualifi[...]

INST ALLA TION A-5 A-5 PRO-CUT 25 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: When using nitrogen gas from a cylinder , the cylinder must have a pressure regulator . • Maximum psi from a nitrogen gas cylinder to th[...]

NOTES A-6 A-6 PRO-CUT 25 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[...]

Section B-1 Section B-1 PRO-CUT 25 T ABLE OF CONTENTS - OPERA TION SECTION - Operation ............................................................................................................................... Section B 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 B-2 B-2 PRO-CUT 25 OPERA TION Read and understand this entire section before operat- ing the machine. SAFETY PRECAUTIONS DESCRIPTION The PRO-CUT 25 is a constant current, continu[...]

OPERA TION B-3 B-3 PRO-CUT 25 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 USER RESPONSIBILITY Because design, fabrication, erection and cutting vari- ables affect the results obtained in applying this type of information, [...]

OPERA TION B-4 B-4 PRO-CUT 25 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 CUTTING CAP ABILITY The PRO-CUT 25 is rated at 25 amps, at 35% duty cycle on a 10 minute basis. If the duty cycle is exceeded, a thermal protector w[...]

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 25 LIMIT A TIONS Do not exceed output current and duty cycle rating of machine. Do not use the PRO-CUT 25 for pipe thaw- ing. CONTROLS AND SETTINGS Whe[...]

OPERA TION B-6 B-6 PRO-CUT 25 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 Direction of Travel 5 ° - 15 ° 10 ° - 20 ° Arc Lag Leading Angle • Use a 5° - 15° leading angle in the direction of the cut. • Finish the [...]

OPERA TION B-7 B-7 PRO-CUT 25 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 PROCEDURE RECOMMENDA TIONS When properly used, plasma arc cutting is a very eco- nomical process. Improper use will result in a very high operating [...]

NOTES B-8 B-8 PRO-CUT 25 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 PRO-CUT[...]

ACCESSORIES C-2 C-2 PRO-CUT 25 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 AL W A YS USE GENUINE LINCOLN ELECTRIC ELECTRODES AND VORTECH ™ NOZZLES • Only Genuine Lincoln Electric consumables yield the best cutting perf[...]

Section D-1 Section D-1 PRO-CUT 25 T ABLE OF CONTENTS -MAINTENANCE- Maintenance ......................................................................................................................... Section D Routine Maintenance ............................................................................................................ ......D-2[...]

MAINTENANCE D-2 D-2 PRO-CUT 25 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 PERIODIC MAINTENANCE Change consumables as required. THERMAL PROTECTION Thermal Detection Devices protect the machine from excessive operating temp[...]

L IN C O L N E L E C T R IC PRO-CUT 25 O N O F F P U R G E POWER GAS PRESSURE THERMAL SAFETY ! R E Q U I R E S 2 0 A / 1 1 5 V B R A N C H C I R C U I T R E Q U I R E S 3 0 A / 1 1 5 V B R A N C H C I R C U I T 2 5 2 0 P C T 2 0 6 1 2 4 3 5 7 MAINTENANCE D-3 D-3 PRO-CUT 25 Return to Section TOC Return to Section TOC Return to Section TOC Return to [...]

NOTES D-4 D-4 PRO-CUT 25 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[...]

Section E-1 Section E-1 PRO-CUT 25 Theory of Operation ............................................................................................................. Section E General Description ....................................................................................................................E-2 Input Line V oltage and Auxiliary T[...]

FIGURE E.2 – INPUT LINE VOL T AGE GENERAL DESCRIPTION The PRO-CUT 25 is an inverter based constant current, continuous contr ol plasma cutting power source. The contr ol system has a safety mechanism to insure that the nozzle and electr ode are in place before cutting or gouging. The PRO-CUT 25 initiates the plasma arc with a simple, yet r eliabl[...]

PRECHARGE AND PROTECTION The input voltage is rectified by the input r ectifier on the inverter board. The r esultant DC voltage is applied to the filter capacitors through the automatic r econnect of the input boar d. The input board also contains prechar ging circuitry for the safe char ging of the input filter capacitors. Once the capacitors are[...]

THEOR Y OF OPERA TION E-4 E-4 PRO-CUT 25 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 115/230/1/50/60 VAC INPUT CN1 2 1 4 3 5 6 7 8 300uH L1 RL3 10/10W R1 V2 V1 B A 1A/250V F1 RL2 RL2 RL2 AC [...]

OUTPUT SECTION AND TORCH The output section contains a relay which, upon r eceiving a pilot signal fr om the control boar d will enable the operation of a pilot arc or a cutting ar c. The printed circuit boar d mounted current sensor r egulates the pilot and cutting current. The output choke, which is in series with both the pilot circuit and the c[...]

CONTROL BOARD The control boar d receives status and analog feedback signals from the inverter boar d, input board, and various sensors. The control cir cuitry interprets these signals, makes decisions and changes the machines mode and output to satisfy the requir ements as defined by the circuitry . The control board sends a signal to the inverter[...]

PROTECTION CIRCUITS Protection cir cuits are designed into the PRO-CUT 25 machine to sense trouble, damages, pr oblems with internal components, and to provide safety . These ar e the main protection cir cuits: OVERLOAD PROTECTION The PRO-CUT 25 is electrically protected fr om producing higher than normal output curr ents. If the output current exc[...]

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[...]

PRO-CUT 25 Section F-1 Section F-1 Tr oubleshooting & Repair Section ................................................................................. Section F How to Use T roubleshooting Guide ....................................................................................F-2 PC Board T roubleshooting Pr ocedures and Replacement .........[...]

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 PRO-CUT 25 HOW TO USE TROUBLESHOOTING GUIDE Service and repair should be performed by only Lincoln Electric Factory T rained Personnel. Unauthorized repairs performed on this equ[...]

PRO-CUT 25 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 ELECTRIC SHOCK can kill. Have an electrician install and service this equipment. T ur n the machine OFF before working on equipment. Do not touch electrically hot part[...]

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 PRO-CUT 25 TROUBLESHOOTING & REP AIR F-4 F-4 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 PRO-CUT 25 TROUBLESHOOTING & REP AIR F-5 F-5 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF M[...]

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 PRO-CUT 25 TROUBLESHOOTING & REP AIR F-6 F-6 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF M[...]

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 PRO-CUT 25 TROUBLESHOOTING & REP AIR F-7 F-7 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 PRO-CUT 25 TROUBLESHOOTING & REP AIR F-8 F-8 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 25 INPUT FIL TER CAP ACITOR DISCHARGE PROCEDURE W ARNING Service and repair should be performed by only Lincoln Electric factory tra[...]

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-10 F-10 PRO-CUT 25 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-11 F-11 PRO-CUT 25 W ARNING MAIN INVER TER BOARD RESIST ANCE TEST 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-12 F-12 PRO-CUT 25 MAIN INVER TER BOARD RESIST ANCE TEST (continued) FIGURE F .2 TEST PROCEDURE 1. Remove main input power to the PRO-CUT 25. 2. R[...]

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 25 MAIN INVER TER BOARD RESIST ANCE TEST (continued) FIGURE F .3 LOCA TION OF IGBT S (6) RIGHT SIDE OF MACHINE (NZL) WRK (EL) Harn[...]

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 25 MAIN INVER TER BOARD RESIST ANCE TEST (continued) 9. Check Diodes D1, D2, & D3 for “shorts” or “opens”. Keep in min[...]

RIGHT SIDE OF MACHINE (NZL) WRK (EL) Harness Plug Plug J1 LEAD 3 LEAD 2 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 25 10. Remove the torch consumables. (Shield cup, Nozzle a[...]

NOTES F-16 F-16 PRO-CUT 25 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-17 F-17 PRO-CUT 25 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 BOARD VOL T AGE TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthori[...]

TEST PROCEDURE 1. Remove input power to the PRO-CUT 25 machine. 2. Remove carrying handle using a 4mm allen wrench. 3. Using a crescent wr ench, carefully r emove the plastic nut fr om around the pressur e regulator located on the top of the machine. 4. Using a 7mm nut driver , r emove the case wraparound. 5. Perform the Capacitor Discharge Procedu[...]

TROUBLESHOOTING & REP AIR F-19 F-19 PRO-CUT 25 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 10. After the relays activate check for 115V AC from both test points AC to CP . See Figure F .7. If this voltage is not presen[...]

NOTES F-20 F-20 PRO-CUT 25 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[...]

F-21 F-21 PRO-CUT 25 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 MAIN INVER TER BOARD VOL T AGE TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. [...]

TEST PROCEDURE 1. Remove input power to the PRO-CUT 25 machine. 2. Remove carrying handle using a 4mm allen wrench. 3. Using a crescent wr ench, carefully r emove the plastic nut fr om around the pressur e regulator located on the top of the machine. 4. Using a 7mm nut driver , remove the case wraparound. 5. Perform the Capacitor Discharge Procedur[...]

10. Carefully test for 12VDC at test points C7. See Figure F .9. See the Wiring Diagram. This is the rectified and r egulated supply for the pulse width modulation circuit. 11. Carefully test for 12VDC at C18 test points. If it is not correct the contr ol board or associated wiring may be faulty . See the Wiring Diagram. See Figure F .9. 12. Carefu[...]

NOTES F-24 F-24 PRO-CUT 25 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 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 electrical shock, please observe all safet[...]

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-26 F-26 PRO-CUT 25 TORCH CONTINUITY AND SOLENOID TEST (continued) TEST PROCEDURE 1. Remove input power to the PRO-CUT 25 machine. 2. Remove carryi[...]

TROUBLESHOOTING & REP AIR F-27 F-27 PRO-CUT 25 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) T ABLE F .1 - TORCH ASSEMBL Y RESIST ANCES TEST CIRCUIT(S) BEING EXPECTED TEST P[...]

NOTES F-28 F-28 PRO-CUT 25 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-29 F-29 PRO-CUT 25 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-30 F-30 PRO-CUT 25 AIR/GAS SOLENOID TEST (continued) TEST PROCEDURE 1. Remove input power to the PRO-CUT 25 machine. 2. Remove carrying handle usi[...]

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 PRO-CUT 25 TROUBLESHOOTING & REP AIR F-31 F-31 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 PRO-CUT 25 TROUBLESHOOTING & REP AIR F-32 F-32 PROCEDURE 1. Remove input power to the PRO-CUT 25 machine. 2. Remove carrying handle using a 4mm allen wrench. 3. Using a cresc[...]

PRO-CUT 25 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 7. A nut is located under the red plastic piece that you previously r emoved. Loosen this nut with a 6mm nut driver and remove. Plastic alignment spacer may come off w[...]

PRO-CUT 25 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 16. Replace the r ed PURGE button. 17. Replace the plastic OUTPUT knob, align it in its original position, and tighten nut. 18. Replace the red cap on the end of the O[...]

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 PRO-CUT 25 TROUBLESHOOTING & REP AIR F-35 F-35 W ARNING INPUT BOARD REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained p[...]

PROCEDURE 1. Remove input power to PRO-CUT 25. 2. Remove carrying handle using a 4mm allen wrench. 3. Using a cr escent wrench, car efully r emove the plastic nut fr om around the pressur e regulator located on the top of the machine. 4. Using a 7mm nut driver , remove the case wraparound. 5. Perform Capacitor Discharge Procedure. Be sure to follow[...]

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 PRO-CUT 25 TROUBLESHOOTING & REP AIR F-37 F-37 FIGURE F.17 – INPUT BOARD REMOVAL Fan Leads Four Leads Switch Leads Mounting Screws Multi-colored Plug Mounting Screws A B AC[...]

NOTES F-38 F-38 PRO-CUT 25 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[...]

PRO-CUT 25 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 W ARNING MAIN INVER TER BOARD REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory [...]

CAUTION PRO-CUT 25 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-40 F-40 FIGURE F.18 – MAIN INVERTER BOARD REMOVAL MAIN INVER TER BOARD REMOV AL & REPLACEMENT (continued) PROCEDURE 1. Re[...]

PRO-CUT 25 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-41 F-41 FIGURE F.19 – INVERTER BOARD LEAD LOCATIONS Leads NZL WRK EL Harness Plug (J1) Harness plugs Lead MAIN INVER TER BOARD REMOV [...]

NOTES F-42 F-42 PRO-CUT 25 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[...]

PRO-CUT 25 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-43 F-43 W ARNING SWITCH REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained person[...]

PRO-CUT 25 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 FIGURE F.20 – SWITCH L IN C O L N E L E C T R IC PRO-CUT 25 O N O FF PU R G E P O W E R G A S P R E S S U R E T H E R M A L S[...]

PRO-CUT 25 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 W ARNING F AN REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personne[...]

PRO-CUT 25 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-46 F-46 FIGURE F.21 – FAN LOCATION L IN C O L N E L E C T R IC PRO-CUT 25 O N O FF PU R G E P O W E R G A S P R E S S U R E T H E R M[...]

PRO-CUT 25 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 F AN REMOV AL AND REPLACEMENT (continued) 7. Using a phillips head screwdriver , r emove the four mounting scr ews on the four [...]

RETEST AFTER REP AIR Should a machine under test be rejected for any r eason requiring the r emoval of any mechanical part that could affect the machine’ s electrical characteristics, or if any electrical components are repair ed or replaced, the machine must be retested. Machine Input and Output Input V olts/Hertz Input Current Rated Output 230/[...]

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC G-1 G-1 PRO-CUT 25 ELECTRICAL DIAGRAMS T ABLE OF CONTENTS -ELECTRICAL DIAGRAMS SECTION- ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION G WIRING DIAGRAM - PROCUT 25 . . .[...]

ELEC TRIC AL DIA GRAMS G-2 P RO-CUT 25 WIRING DIA GRAM - PRO-CUT 25 115/230/1/50/60 VAC INPUT CN1 2 1 4 3 5 6 7 8 300uH L1 RL3 10/10W R1 V2 V1 B A 1A/250V F1 RL2 RL2 RL2 AC CP CP A C L1 RL1 RL2 115VAC 230V T1 115V RL1 L1 15VAC 15VAC SAFETY +28VDC SEC GND OVLOAD 115/230 +12VDC AC CP CP AC CN2 6 9 10 2 20 15 16 +15Vrms EV1 NO COM NC 12VDC PS2 PS1 86 [...]

ELEC TRIC AL DIA GRAMS G-3 P RO-CUT 25 WIRING DIA GRAM W/ADDITIONAL INFO pressure Schematic 98056 (SIPC 25) Schematic 99016 ( SPA25) Schematic 98044 Purge Switch (n.o.) Gas Psi . Thermo Safety led Input Power 8 vdc when open for correct pressure RL1 RL3 Auto reconnect card RL1 (control bd mounted) 50hz /60 hz RPM’s 2700/ 3100 amps .13 / .12 runs [...]

ELEC TRIC AL DIA GRAMS G-4 P RO-CUT 25 SCHEMA TIC- CONTROL PRINTED CIRCUIT BO ARD - SHEET 1 G-4 NO TE: This diagr am is for r ef erence only . It may not be accur ate for all machines cov ered b y this manual. Re t ur n t o Se ct io n T OC Re tur n to Se ct io n T OC Re t ur n t o Se ct io n T OC Re tur n to Se ct io n T OC Re t ur n t o Ma ste r T[...]

ELEC TRIC AL DIA GRAMS G-5 P RO-CUT 25 SCHEMA TIC- CONTROL PRINTED CIRCUIT BO ARD - SHEET 2 G-5 NO TE: This diagr am is for r ef erence only . It may not be accur ate for all machines cov ered b y this manual. Re t ur n t o Se ct io n T OC Re tur n to Se ct io n T OC Re t ur n t o Se ct io n T OC Re tur n to Se ct io n T OC Re t ur n t o Ma ste r T[...]

ELEC TRIC AL DIA GRAMS G-6 P RO-CUT 25 SCHEMA TIC- CONTROL PRINTED CIRCUIT BO ARD - SHEET 3 G-6 NO TE: This diagr am is for r ef erence only . It may not be accur ate for all machines cov ered b y this manual. Re t ur n t o Se ct io n T OC Re tur n to Se ct io n T OC Re t ur n t o Se ct io n T OC Re tur n to Se ct io n T OC Re t ur n t o Ma ste r T[...]

NO TE: Lincoln Elec tric assumes no responsibilit y for liablilities resulting fr om board lev el troubleshoo ting. PC Board repair s will inv alidate your factory w arranty . Individual P rint ed Cir cuit Board Component s are not a v aila ble fr om Lincoln Electric . This information is pr o- vided for r efer ence only . Lincoln Elec tric discour[...]

NO TE: Lincoln Elec tric assumes no responsibilit y for liablilities resulting fr om board lev el troubleshoo ting. PC Board repair s will inv alidate your factory w arranty . Individual P rint ed Cir cuit Board Component s are not a v aila ble fr om Lincoln Electric . This information is pr o- vided for r efer ence only . Lincoln Elec tric discour[...]

ELEC TRIC AL DIA GRAMS G-9 P RO-CUT 25 PC 25 T ORCH DET A ILS 5% 75% ELECTRODE SOL. ENERGIZED (surface area is great) Cup “O” rings must be good. electrode is held to the nozzle. COMPRESSED AIR INPUT 20% VERY LITTLE COMPRESSED AIR FLOWING at tip. %= AIR FLOW AIR IS FLOWING & ELECTRODE SOL. IS “ON”. HOLDS ELECTRODE TO NOZZLE ELECTRODE SO[...]

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[...]