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PRO-CUT
™
80
For use with machine code numbers 10573, 10574, 10577, 10578
SVM146-A
September, 1999
Safety Depends on You
Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation
. . . and thoughtful operation on your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And, most importantly, think before you act and be careful.
SERVICE MANUAL
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.
The Above For Diesel Engines
The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.
The Above For Gasoline Engines
i
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040,
Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the
Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.
____________________________________________________
1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.
1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.
ELECTRIC AND
MAGNETIC FIELDS may be dangerous
____________________________________________________
1.c. Do not add the fuel near an open flame welding arc or when the engine is running. Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes have been eliminated.
____________________________________________________
1.d. Keep all equipment safety guards, covers and devices in position and in good repair.Keep
hands, hair, clothing and tools away from Vbelts, gears, fans and all other moving parts when starting, operating or repairing equipment.
2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines
2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.
2.c. Exposure to EMF fields in welding may have other health effects which are now not known.
2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:
____________________________________________________
1.e. In some cases it may be necessary to remove safety guards to perform required maintenance.
Remove guards only when necessary and replace them when the maintenance requiring their removal is complete.
Always use the greatest care when working near moving parts.
___________________________________________________
1.f. Do not put your hands near the engine fan. Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate.
2.d.1. Route the electrode and work cables together - Secure them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and work cables. If the electrode cable is on your right side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded.
2.d.5. Do not work next to welding power source.
PRO-CUT 80
ii
ELECTRIC SHOCK can kill.
3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full area of physical contact with work and ground.
In addition to the normal safety precautions, if welding must be performed under electrically hazardous conditions (in damp locations or while wearing wet clothing; on metal structures such as floors, gratings or scaffolds; when in cramped positions such as sitting, kneeling or lying, if there is a high risk of unavoidable or accidental contact with the workpiece or ground) use the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f. Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders.
3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
SAFETY
ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable screening and/or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal.
FUMES AND GASES can be dangerous.
5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases.When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep fumes and gases away from the breathing zone. When welding with electrodes which require special ventilation such as stainless or hard facing (see instructions on container or MSDS) or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes, keep exposure as low as possible and below Threshold Limit Values (TLV) using local exhaust or mechanical ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required. Additional precautions are also required when welding on galvanized steel.
5.b. Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to form phosgene, a highly toxic gas, and other irritating products.
5.c. Shielding gases used for arc welding can displace air and cause injury or death. Always use enough ventilation, especially in confined areas, to insure breathing air is safe.
5.d. Read and understand the manufacturer’s instructions for this equipment and the consumables to be used, including the material safety data sheet (MSDS) and follow your employer’s safety practices. MSDS forms are available from your welding distributor or from the manufacturer.
5.e. Also see item 1.b.
ii
PRO-CUT 80
iii
SAFETY
WELDING SPARKS can cause fire or explosion.
6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent the welding sparks from starting a fire.
Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the equipment being used.
6.c. When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even though they have been “cleaned”. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a welding area.
6.g. Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains, crane cables or other alternate circuits.
This can create fire hazards or overheat lifting chains or cables until they fail.
6.h. Also see item 1.c.
CYLINDER may explode if damaged.
7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to physical damage.
• A safe distance from arc welding or cutting operations and any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.
7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
FOR ELECTRICALLY powered equipment.
8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
iii
PRO-CUT 80
iv
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 suivantes:
Sûreté Pour Soudage A L’Arc
1.
Protegez-vous contre la secousse électrique: a.
Les circuits à l’électrode et à la piéce sont sous tension quand la machine à souder est en marche. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les vétements mouillés. Porter des gants secs et sans trous pour isoler les mains.
b.
Faire trés attention de bien s’isoler de la masse quand on soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grande partie du corps peut être en contact avec la masse.
c.
Maintenir le porte-électrode, la pince de masse, le câble de soudage et la machine à souder en bon et sûr état defonctionnement.
d.
Ne jamais plonger le porte-électrode dans l’eau pour le refroidir.
e.
Ne jamais toucher simultanément les parties sous tension des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut
être le total de la tension à vide des deux machines.
2.
Dans le cas de travail au dessus du niveau du sol, se protéger contre les chutes dans le cas ou on recoit un choc. Ne jamais enroule le câble-électrode autour de n’importe quelle partie du corps.
3.
Un coup d’arc peut être plus sévère qu’un coup de soliel, donc: a.
Utiliser un bon masque avec un verre filtrant approprié ainsi qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou quand on regarde l’arc.
b.
Porter des vêtements convenables afin de protéger la peau de soudeur et des aides contre le rayonnementde l’arc.
c.
Protéger l’autre personnel travaillant à proximité au soudage à l’aide d’écrans appropriés et non-inflammables.
4.
Des gouttes de laiter en fusion sont émises de l’arc de soudage. Se protéger avec es vêtements de protection libres de l’huile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.
5.
Toujours porter des lunettes de sécurité dans la zone de soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l’on pique le laitier.
6.
Eloigner les matériaux inflammables ou les recouvrir afin de prévenir ttout risque d’incendie dû étincelles.
SAFETY
7. Quand on ne soude pas, poser la pince à une endroit isolé de la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible de la zone de travail qu’il est pratique de la faire. Si on place la masse sur la charpente de la construction ou d’autres endroits éloignés de la zone de travail, on augmente le risque de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou atres circuits. Cela peut provoquer des risques d’incendie ou d’echauffement des chaines et des câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles galvanisées plombées, ou cadmiées ou tout autre métal qui produit des fumées toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant d’opéerations de dégraissage, nettoyage ou pistolage. La chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs du solvant pour produire du phosgéne (gas fortement roxique) ou autres produits irritants.
iv
PRÉCAUTIONS DE SÛRETÉ POUR LES
MACHINES À SOUDER À TRANSFOR-
MATEUR ET À REDRESSEUR
1.
Relier à la terre le chassis du poste conformement au code de l’électricité et aux recommendations du fabricant. Le dispositif de montage ou la piece à souder doit être branché à une bonne mise à la terre.
2.
Autant que possible, l’installation et l’entretien du poste seront effectués par un électricien qualifié.
3.
Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.
4.
Garder tous les couvercles et dispostifis de sûreté à leur place.
PRO-CUT 80
v
MASTER TABLE OF CONTENTS FOR ALL SECTIONS
RETURN TO MAIN INDEX
Page
Parts Manual ....................................................................................................................P-340 Series v
PRO-CUT 80
Section A-1
TABLE OF CONTENTS
- INSTALLATION SECTION -
Installation
Section A-1
PRO-CUT 80
A-2
INSTALLATION
TECHNICAL SPECIFICATIONS - PRO-CUT 80
Single Phase Input
Voltage and Hertz
208/1/60
230/1/60
460/1/60
INPUT RATINGS
Input Currents
87
81
48
Rated Output Amps
80
80
80
A-2
Three Phase Input
Voltage and Hertz
208/3/60
230/3/60
460/3/60
Input Currents
48
44
25
Rated Output Amps
80
80
80
230/1/60
Duty Cycle
60%
100%
IDLE CURRENT AND WATTS
IDLE CURRENT AND WATTS
0.61 Amps
RATED OUTPUT
140 Watts
Rated Output Amps
80
60
Current Range
35 - 85 Amps
OUTPUT
Open Circuit Voltage
335VDC Maximum
Pilot Current
20 Amps @ 100%
Duty Cycle
PRO-CUT 80
A-3
INSTALLATION
TECHNICAL SPECIFICATIONS (Cont’d) - PRO-CUT 80
GAS REQUIREMENTS
Required Gas Flow Rate
70 PSI @ 480 SCHF
(4.8 Bar. @ 13550 LHR)
Required Gas Inlet Pressure
80 to 150 PSI
(5.4 Bar. to 10.2 Bar.)
RECOMMENDED INPUT WIRE AND FUSE SIZES
For all plasma cutting applications based on U.S. National Electrical Code
Ambient Temperature 30°C or Less
AC Input Voltage at
60 Hertz
Fuse (Super Lag)
Circuit Breaker
(Delay Type)
Type 75°C
Copper Wire in Conduit AWG
(IEC) Sizes
230VAC Single Phase
460VAC Single Phase
230VAC Three Phase
460VAC Three Phase
Height
100 Amps
60 Amps
60 Amps
40 Amps
#4 (21.1mm
2 )
#8 (8.4mm
2 )
#8 (8.4mm
2 )
#10 (5.3mm
2 )
PHYSICAL DIMENSIONS
Width Depth
#4 (21.1mm
2 )
#8 (8.4mm
2 )
#8 (8.4mm
2 )
#10 (5.3mm
2 )
16.5 Inches
419 mm
13.75 Inches
349 mm
29.5 Inches
749 mm
Weight with
Torch Cable
98 lbs. (44.5 kg.)
(25 ft. cable)
113 lbs. (51.4 kg.)
(50 ft. cable)
A-3
PRO-CUT 80
A-4 A-4
INSTALLATION
Read this entire installation section before you start installation.
LIFTING AND MOVING
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK can kill.
• Turn the input power OFF at the disconnect switch or fuse box and discharge input capacitors before working inside the equipment.
• Do not touch electrically hot parts or electrodes with your skin or wet clothing.
• Always connect the 80 grounding terminal (located on the side of the Case Back Assembly) to a good electrical earth ground.
• Always wear dry, insulating gloves.
• Turn the 80 Power Switch OFF when connecting power cord to input power.
WARNING
FALLING EQUIPMENT can cause injury.
• Do not use the pull handle on the optional undercarriage, if installed, to lift the machine. This handle is not designed to support the full weight of the machine. Using it to lift the machine could cause personal injury or damage to the machine.
• Either the front or rear handles or both may be used to lift or move the machine.
Only qualified personnel should install, use, or service this equipment.
SELECT SUITABLE LOCATION
Place the PRO-CUT 80 where clean cool air can freely circulate in through the rear louvers and out through the front/bottom opening. Dirt, dust or any foreign material that can be drawn into the machine should be kept at a minimum. Failure to observe these precautions can result in excessive operating temperatures and nuisance shutdown of the machine.
A source of clean, dry air or nitrogen must be supplied to the PRO-CUT 80. Oil in the air is a severe problem and must be avoided. The supply pressure must be between 80 and 150 psi. The flow rate is approximately 6.0 cfm (170 l/min.). Failure to observe these precautions could result in excessive operating temperatures or damage to the torch.
STACKING
The PRO-CUT 80 cannot be stacked.
TILTING
The PRO-CUT 80 must be placed on a stable, level surface so it will not topple over.
HIGH FREQUENCY INTERFERENCE
PROTECTION
The PRO-CUT 80 employs a touch start mechanism for arc initiation. This eliminates high frequency emissions from the machine as compared with spark gap and solid state type high frequency generators. Keep in mind, though, that these machines may be used in an environment where other high frequency generating machines are operating. By taking the following steps, you can minimize high frequency interference.
• Make sure the power supply chassis is connected to a good earth ground. The work terminal ground does
NOT ground the machine frame.
• Keep the work ground clamp isolated from other work clamps that have high frequency.
• If the ground clamp cannot be isolated, then keep the clamp as far as possible from other work clamp connections.
• When the machine is enclosed in a metal building, several good earth driven electrical grounds around the periphery of the building are recommended.
Failure to observe these recommended installation procedures may cause improper function of the Pro-Cut or possibly even damage the control system or power supply components.
PRO-CUT 80
A-5 A-5
INSTALLATION
INPUT CONNECTIONS
WARNING
ELECTRIC SHOCK can kill.
• Have a qualified electrician install and service this equipment.
• Turn the input power off at the fuse box before working on this equipment.
• Do not touch electrically hot parts.
GROUND CONNECTION
The frame of the PRO-CUT 80 must be properly grounded.
A ground terminal marked with the symbol is mounted on the case bottom directly behind the input power switch for this purpose. The ground lead of the input power cord that is attached to the machine must be connected to this ground terminal. See the
National Electric Code for details on proper grounding methods. Install in accordance with all local and national electrical codes.
Before installing the machine, check that input supply voltage, phase, and frequency are the same as the machine’s voltage, phase, and frequency as specified on the machine’s rating plate. See Figure A.1.
FIGURE A.1 – RATING PLATE LOCATION
1
INPUT POWER CORD CONNECTOR
INSTALLATION
The PRO-CUT 80 is supplied with one 11 foot (3.35m)
#8 AWG 3 lead input power cord already connected to the machine. A cord connector provides a strain relief for the input power cord as it passes through the left rear access hole. The cord connector is designed for a cord diameter of .40 - 1.03 in (10.2 - 26.2mm) if it becomes necessary to install a different input cord.
See Figure A.1.
For three phase connection: Replace the input power cord with a #10 AWG 4 lead cable.
Connect the leads of the cable to a fused power panel.
Make sure the green lead is connected to the panel and the panel is connected to a good earth ground.
Install in accordance with all local and national electric codes.
2
3
INPUT WIRE AND FUSE SIZE
Fuse the input circuit with the super lag fuses or delay
type circuit breakers recommended on the Technical
Specifications page. Choose an input and grounding
wire size according to local or national codes; also see
the Technical Specifications page. Using fuses or
circuit breakers smaller than recommended may result in “nuisance” shut-offs from inrush currents, even if you are not cutting at high currents.
1. CASE BACK
2. RATING PLATE
3. POWER CORD CONNECTOR WITH STRAIN RELIEF
The PRO-CUT 80 should be connected only by a qualified electrician. Installation should be made in accordance with the U.S. National Electrical Code, all local codes, and the information detailed below.
PRO-CUT 80
A-6
INSTALLATION
FIGURE A.2 – RECONNECTION DIAGRAM RECONNECT PROCEDURE
When received directly from the factory, the machines are internally connected for 230 VAC. Reconnection will be necessary if a higher input voltage is used. To reconnect the Pro-Cut to 460 VAC or to connect back to 230 VAC, follow the directions as outlined below.
Follow this procedure ONLY while the Pro-Cut is disconnected from the input power.
CAUTION
Failure to follow these instructions can cause immediate failure of components in the welder.
1. Open the access door on the side of the machine.
Connection instructions are also included on the inside of the door.
2. For 230: Position the large switch to 200-230. See
Figure A.2.
For 460: Position the large switch to 380-460. See
Figure A-2.
3. Move the “A” lead to the appropriate terminal.
RECONNECT PROCEDURE
WARNING
• Disconnect input power before
inspecting or servicing machine.
• Do not operate with wraparound
removed.
ELECTRIC
SHOCK
CAN KILL
• Do not touch electrically live parts.
• Only qualified persons should install,
use, or service this equipment.
1. BE SURE POWER SWITCH IS OFF.
2. CONNECT LEAD 'A' TO DESIRED INPUT VOLTAGE RANGE.
440 - 460V
380 - 415V
'A'
220 - 230V
200 - 208V
3. POSITION SWITCH TO DESIRED INPUT VOLTAGE RANGE.
VOLTAGE = 380 - 460V
A-6
VOLTAGE = 200 - 230V
PRO-CUT 80
A-7 A-7
INSTALLATION
GAS INPUT CONNECTIONS
Supply the PRO-CUT 80 with clean compressed air or nitrogen.
• Supply pressure must be between 80 psi and 150 psi.
• Flow rate should be approximately 6.0 cfm (170
I/min.).
NOTE: Oil in the air supply to the PRO-CUT 80 can cause severe problems. Use only a clean air supply.
• Connect the gas supply to the PRO-CUT 80’s pneumatic nipple at the air filter. See Figure A.3.
• Compressed gas should be supplied to the fitting connection mounted on the filter at the rear of the machine. If necessary, this fitting can be removed allowing plumbing access through the 1/4 in.
(6.4mm) NPT input port on the filter body.
FIGURE A.3 - COMPRESSED GAS CONNECTION
4
1
3
2
WARNING
CYLINDER could explode if damaged.
• Keep cylinder upright and chained to a fixed support.
• Keep cylinder away from areas where it could be damaged.
• Never lift machine with cylinder attached.
• Never allow the cutting torch to touch the cylinder.
• Keep cylinder away from live electrical parts.
• Maximum inlet pressure 150 psi.
1. CASE BACK
2. PNEUMATIC NIPPLE
3. AIR FILTER
4. FLEX TUBE (TO REGULATOR INSIDE MACHINE)
NOTE: When using nitrogen gas from a cylinder, the cylinder must have a pressure regulator.
• Maximum psi from nitrogen gas cylinder to PRO-
CUT 80 regulator should never exceed 150 psi.
• Install a hose between the nitrogen gas cylinder regulator and the PRO-CUT 80 gas inlet.
PRO-CUT 80
A-8 A-8
INSTALLATION
OUTPUT CONNECTIONS
TORCH CONNECTION
The PRO-CUT 80 is supplied from the factory with a
PCT 80 cutting torch. Additional cutting torches can be ordered from the K1571 series. Hand-held and mechanized torches come with 25 or 50 foot cables.
All torches are connected to the Pro-Cut with a quick connect at the case front for easy change over. See
Figure A-4.
For more information on the torch and its components, refer to the PCT 80 Operator’s Manual (IM595).
Output
Control
Knob
Consumable
Storage
(behind door)
FIGURE A.4 - TORCH CONNECTION
AT CASE FRONT
Status
Indicators
Reset
Button
Gas
Purge
Button
Gas
Regulator
Gauge
Gas
Regulator
Knob
PRO-CUT 80
Torch
Connector
Work
Cable
Interface
Connector
Input
Power
Switch
PRO-CUT 80
Section B-1
TABLE OF CONTENTS
- OPERATION SECTION -
Operation ...............................................................................................................................
Section B
Section B-1
PRO-CUT 80
B-2
OPERATION
OPERATING INSTRUCTIONS
Read and understand this entire section of operating instructions before operating the machine.
SAFETY INSTRUCTIONS
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or electrodes with your skin or wet clothing.
• Insulate yourself from the work and ground.
• Always wear dry, insulating gloves.
FUMES AND GASES can be dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to remove fumes from breathing zone.
CUTTING SPARKS can cause fire or explosion.
• Keep flammable material away.
• Do not cut containers that have held combustibles.
ARC RAYS can burn.
• Wear eye, ear, and body protection.
PLASMA ARC can injure.
• Keep your body away from nozzle and plasma arc.
• Operate the pilot arc with caution. The pilot arc is capable of burning the operator, others, or even piercing safety clothing.
Observe additional Safety Guidelines detailed in the beginning of this manual.
PRO-CUT 80
B-2
B-3
GENERAL DESCRIPTION
OPERATIONAL FEATURES AND
CONTROLS
OPERATION
DESIGN FEATURES AND
ADVANTAGES
The PRO-CUT 80 is an inverter based constant current, continuous control plasma cutting power source.
It provides superior and reliable starting characteristics, cutting visibility and arc stability. When cutting expanded metal, the PRO-CUT 80 out-performs the competition due to its quick, clean response to arc transfers. The power supply design provides high transfer-to-cut distances, which makes pierce cutting more reliable with less nozzle wear. The control system has a safety mechanism to insure that the nozzle and electrode are in place before cutting or gouging. This is extremely important due to the high voltages involved.
The PRO-CUT 80 comes standard with an air regulator, coarse air filter, and pressure gauge. There are six different torch and cable systems to choose from: hand-held torch with 25’ or 50’ cable, machine and robotic torch both with 25’ and 50’ cable.
Consumables are included so that cutting can begin right out of the box. Consumables can also be ordered as individual packages.
The PRO-CUT 80 initiates the plasma arc with a simple, yet reliable, touch-start mechanism. This system eliminates many of the failure problems associated with hi-frequency start systems. The PRO-CUT 80 is capable of cutting with nitrogen or air.
The PRO-CUT 80 is controlled by a microprocessorbased control board. The machine performs rudimentary self troubleshooting when powered up, which aids in field servicing.
RECOMMENDED PROCESSES AND
EQUIPMENT
The PRO-CUT 80 is capable of all cutting and gouging applications within its output capacity of 35 to 85 amps. These applications include thin gage sheet metal and expanded metal.
The PRO-CUT 80 comes with an ON/OFF POWER
SWITCH, OUTPUT CURRENT CONTROL, PURGE
BUTTON, STATUS INDICATORS and a SAFETY
RESET BUTTON. See Figure B.2 and related discus-
sion.
B-3
The microprocessor controlled PRO-CUT 80 design makes plasma cutting and gouging tasks uncomplicated. This list of design features and advantages will help you understand the machine's total capabilities so that you can get maximum use from your machine.
• Light weight and portable design for industrial use.
• Continuous control, 35 - 85 amps.
• Reliable touch start mechanism for plasma arc initiation.
• Unique microprocessor controlled starting sequence for safe and consistent starting.
• Rapid arc transfer for fast cutting of expanded metal.
• High transfer distance for ease of use.
• Input overvoltage protection.
• 3.0 second pilot arc.
• Purge momentary push button.
• Air regulator and pressure gauge located on the front of machine for convenience.
• ”Parts-in-Place” mechanism to detect proper installation of consumables and torch.
• Automatic detection of faulty output control.
• In-line coarse air filter.
• Preflow/Postflow timing. Preflow is eliminated if arc is re-initiated in Postflow.
• Thermostatic Protection.
• Solid state overcurrent protection.
• Works with pure nitrogen for cutting nonferrous materials.
• Reconnectable for multiple input voltages.
• Quick disconnect torch.
• Display indicators for machine status.
• Unique electrode and Vortech™ nozzle design for optimum cooling and long life.
• Swirl texture inside Vortech™ nozzle for better starting reliability and higher quality cuts.
• Unique drag cup design for durability and elimination of double arcing.
PRO-CUT 80
B-4
OPERATION
CUTTING CAPABILITY
The PRO-CUT 80 is rated at 80 amps, at 60% duty cycle on a 10 minute basis or 60 amps, at 100% duty cycle. If the duty cycle is exceeded, a thermal 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 PRO-CUT 80 when cutting mild steel. The graph plots cut thickness vs. torch travel speed with a torch standoff of 0.15 in.
(3.8mm).
Example: 0.5 material
Amps Speed (IPM)
55
80
25
35
FIGURE B.1 – LINCOLN’S PRO-CUT 80 MILD STEEL CUT CAPACITY CHART
Lincoln's PRO-CUT 80
Mild Steel Cut Capacity Chart
100
B-4
80
60
40
20
0
0.000
0.125
25 A
35 A
0.250
0.375
Material Thickness
0.500
0.625
55 A
0.750
80 A
1.00
CONSUMABLE LIFE
The expected life for the PRO-CUT 80's electrode under normal operating conditions is approximately
160 starts/cuts. An erosion of .060 in. (1.5mm) is typical for end of electrode life. However, the electrode may last longer. A green and erratic arc will indicate definite electrode failure, and the electrode should be replaced immediately.
It is recommended that consumables be replaced in complete sets. (Example: Electrode and Nozzle). This will maximize the performance of the PRO-CUT 80 system.
LIMITATIONS
Do not exceed output current and duty cycle rating of machine. Do not use the PRO-CUT 80 for pipe thawing.
PRO-CUT 80
B-5 B-5
OPERATION
CONTROLS AND SETTINGS
FIGURE B.2 - CASE FRONT CONTROLS
Status
Indicators
Reset
Button
Gas
Purge
Button
Gas
Regulator
Gauge
Output
Control
Knob
Gas
Regulator
Knob
Occasionally, the pilot arc may sputter or start intermittently. This is aggravated when the consumables are worn or the air pressure is too high. Always keep in mind that the pilot arc is designed to transfer the arc to the workpiece and not for numerous starts without cutting.
When the pilot arc is started, a slight impulse will be felt in the torch handle. This occurrence is normal and is the mechanism which starts the plasma arc. This impulse can also be used to help troubleshoot a "no start" condition.
Consumable
Storage
(behind door)
Torch
Connector
Work
Cable
PRO-CUT 80
Interface
Connector
Input
Power
Switch
OUTPUT CURRENT CONTROL KNOB - Adjusts the amount of cutting current applied. Affects cutting speed, dross formation, cut width, heat zone and travel speed.
TORCH CONNECTOR - Quick- connect type coupling for the PCT 80 cutting torch.
WORK CABLE - Provides clamp and cable connection to workpiece.
ON/OFF POWER SWITCH - Turns machine on or off.
GAS REGULATOR KNOB - Adjusts compressed gas pressure delivered to the torch. Length of torch hose is an adjustment factor. Optimum setting is 70-75 psi.
The gas purge button must be pressed in to set pressure.
GAS REGULATOR GUAGE - Provides gas presssure reading as set by the gas regulator knob.
GAS PURGE BUTTON - Used to check or set gas pressure. Push in and hold to check pressure, then continue to hold to set the pressure. Shuts off gas when released.
RESET BUTTON - Used to reset the machine following a safety circuit trip.
STATUS (DISPLAY) BOARD INDICATORS - Four lights indicating Power, Gas Low, Thermal and Safety.
PILOT ARC CONSIDERATIONS
The Pro-Cut has a smooth, continuous pilot arc. The pilot arc is only a means of transferring the arc to the workpiece for cutting. Repeated pilot arc starts, in rapid succession, is not recommended as these starts will generally reduce consumable life.
PRO-CUT 80
CUTTING OPERATION
When preparing to cut or gouge, position the machine as close to the work as possible. Make sure you have all materials needed to complete the job and have taken all safety precautions. It is important to follow these operating steps each time you use the machine.
• Turn the machine's ON/OFF POWER SWITCH to the OFF position.
• Connect the air supply to the machine.
• Turn the main power and the machine power switch on.
- The fan should start.
- The pre-charge circuit will operate for 3 seconds, then the green "Power" status indicator should turn on.
- If the "SAFETY" status indicator is lit, push the
"Reset" button. If there is no problem, the status indicator will go off. If there is a problem, refer to
"STATUS INDICATOR" in this section.
• Be sure that the work lead is clamped to the workpiece before cutting.
• Set the output current control knob for maximum current for high cutting speed and less dross forma-
tion per Figure B.1. Reduce the current, if desired,
to reduce the kerf (cut) width, heat affected zone or travel speed as required.
• Push-in and hold the Purge button to check or set the gas pressure. Pull the pressure regulator cap out and turn it to set the pressure.
- Adjust the gas regulator for 70 PSI for 25 foot
(7.62m) torches or 75 PSI for 50 foot (15.24m) torches.
- Release the Purge button.
B-6 B-6
OPERATION
- The gas will immediately turn off. The pressure gauge may show an increase in pressure after the air turns off, but this is normal. Do NOT reset the pressure while the air is NOT flowing.
• When ready to cut, place the torch near the work, make certain all safety precautions have been taken and pull the trigger.
- The air will flow for a preflow time of 2 seconds and the pilot arc will start. (This is true unless the machine is in postflow, then the preflow time is skipped and the pilot arc will start immediately.)
- The pilot arc will run for 3 seconds and shut off unless the arc is brought in contact with the work and the arc is transferred. Avoid excessive pilot arc time by transferring the arc to the workpiece quickly to improve parts life.
- When the arc is brought within 1/4 in. (6.4mm) from the workpiece the arc will transfer, the current will ramp up to the setting on the control panel, and the cut can last indefinitely (or until the duty cycle of the Pro-Cut is exceeded). Do not touch the nozzle to the work when cutting.
Damage to the consumables may result.
• Pierce the workpiece by slowly lowering the torch onto the metal at a 30° angle away from the operator. This will blow the dross away from the torch tip.
Slowly rotate the torch to vertical position as the arc becomes deeper.
TORCH AT 30
0
ANGLE
TO PIERCE
ROTATE TO
90 0 ANGLE TO CUT
5 ° - 15 ° Leading Angle
10 ° - 20 °
Arc Lag
Direction of Travel
• Finish the cut to be made and release the trigger.
• When the trigger is released, the arc will stop.
- The gas will continue to flow for 10 seconds of postflow. If the trigger is activated within this time period, the pilot arc will immediately restart.
• If the dross is difficult to remove, reduce the cutting speed. High speed dross is more difficult to remove than low speed dross.
• The right side of the cut is more square than the left as viewed along the direction of travel.
• Clean spatter and scale from the nozzle and drag cup frequently.
• For gouging, tilt the torch about 45° from the workpiece and hold the nozzle 1/8 in. (3.2mm) to 3/16”
(4.7mm) above the workpiece.
ANGLE
OF APPROACH
90 0
VER TICAL ANGLE
CUT
TORCH HELD AT
45 0 ANGLE
THROUGHOUT GOUGE
• Hold the nozzle standoff 1/8 in. (3.2mm) to 3/16 in.
(4.7mm) above the workpiece during cutting. Do not let the torch nozzle touch the work or carry a long arc.
ANGLE
MAINTAINED
THROUGHOUT
GOUGE
• Keep moving while cutting. Cut at a steady speed without pausing. Maintain the cutting speed so that the arc lag is 10° to 20° behind the travel direction.
SAFETY STATUS INDICATOR
• Use a 5° - 15° leading angle in the direction of the cut.
• If the "SAFETY" status indicators light at any time, check the following:
• Use the drag cup to maintain constant standoff for better cut quality and to protect the nozzle from
- Check the assembly of the torch consumables. If they are not properly in place, the machine will not spatter.
start. Make sure that the shield cup is hand
• Use the drag cup with a metal template to prevent nozzle double arcing.
PRO-CUT 80 tight. Do not use pliers or overtighten.
B-7 B-7
OPERATION
WARNING
ELECTRIC SHOCK can kill.
• Turn off machine at the disconnect switch on the front of the machine before tightening, cleaning or replacing consumables.
PREHEAT TEMPERATURE FOR
PLASMA CUTTING
Preheat temperature control is not necessary in most applications when plasma arc cutting or gouging.
Preheat temperature control may be necessary on high carbon alloy steels and heat treated aluminum for crack resistance and hardness control. Job conditions, prevailing codes, alloy level, and other considerations may also require preheat temperature control.
The recommended minimum preheat temperature for plate thickness up to 1/2 in. (12.7mm) is 70°F (21.1°C).
Higher temperatures may be used as required by the job conditions and/or prevailing codes. If cracking or excessive hardness occurs on the cut face, higher preheat temperature may be required.
- 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
“Suggestions for Extra Utility from the Pro-Cut
- Check the condition of the electrode. If the end has a crater-like appearance, replace it along with the nozzle. The maximum wear depth of the electrode is approximately .062 in. (1.6mm). A green and erratic arc will indicate definite electrode failure.
The electrode should be replaced immediately.
• Replace the nozzle when the orifice exit is eroded away or oval shaped.
• After the problem is found, or if there is nothing apparently wrong, reset the machine by pressing the "Reset" button. (It is possible for electrical noise to trip the safety circuit on rare occasions. This should not be a regular occurrence.)
• If the machine does not reset or continues to trip, consult the Troubleshooting Section.
• Use the proper cutting or gouging procedures referred to in “Procedure Recommendations” below.
PROCEDURE RECOMMENDATIONS
When properly used, plasma arc cutting or gouging is a very economical process. Improper use will result in a very high operating cost.
GENERAL - IN ALL CASES
• Follow safety precautions as printed throughout this manual and on the machine.
THIN GAUGE SHEET METAL
Torch Standoff Machine Output Setting
45
USER RESPONSIBILITY
Because design, fabrication, erection, and cutting variables affect results, the serviceability of a product or structure is the responsibility of the user. Variation such as plate chemistry, plate surface condition (oil, scale), plate thickness, preheat, quench, gas type, gas flow rate and equipment may produce results different from those expected. Some adjustments to procedures may be necessary to compensate for unique individual conditions. Test all procedures duplicating actual field conditions.
DRAG thru 1/16"
Standoff
Output set below 45 Amps.
Output Setting
Min. thru Mid. Range
• The nozzle may be dragged on the metal surface, touching it lightly to the surface after piercing a hole.
Current control should be set below the mid-range.
• Do not allow cable or body to contact hot surface.
PRO-CUT 80
B-8 B-8
OPERATION
THICK SECTIONS OF METAL
Torch Standoff
1/8" thru 3/16"
Standoff
45
Output set above 45 Amps.
Machine Output Setting
Output Setting
Mid. thru Max. Range
• The best quality and consumable life will be obtained by holding the torch off the surface about
3/16 in. (4.7mm). Too 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 proper standoff. The only time not to use the drag cup when the output control is set above mid-range is in special, tight corners. Always hold at least a 1/8 in.
(3.2mm) standoff in those situations.
• If piercing is required, slowly lower the torch at an angle of about 30° to blow the dross away from the torch tip and slowly rotate the torch to a vertical position as the arc becomes deeper. This process will blow a lot of molten metal and dross. Be careful! Blow the dross away from the torch, the operator and any flammable objects.
• Where possible, start the cut from the edge of the workpiece.
• Keep moving! A steady speed is necessary. Do not pause.
• Do not allow the torch cable or body to contact a hot surface.
SUGGESTIONS FOR EXTRA UTILITY
FROM THE PRO-CUT SYSTEM
WARNING
ELECTRIC SHOCK can kill.
• Turn off machine at the disconnect switch on the front of the machine before tightening, cleaning or replacing consumables.
1. Occasionally an oxide layer may form over the tip of the electrode, creating an insulating barrier between the electrode and nozzle. This will result in the tripping of the Pro-Cut's safety circuit. When this happens, turn the power off, remove the nozzle and electrode and use the electrode to rub against the inside bottom surface of the nozzle.
This will help remove any oxide buildup. Replace the nozzle, turn on the power and continue cutting.
If the Parts-in-Place circuit (safety status indicator light) continues to trip after cleaning the consumables, replace them with a new set. Do not continue to cut with excessively worn consumables as this can cause damage to the torch head and will degrade cut quality.
2. To improve consumable life, here are some suggestions that may be useful: a. Never drag the nozzle on the work surface if the output control knob is above 45 Amps. b. Make sure the air supply to the Pro-Cut is clean and free of oil. Use several extra in-line filters if necessary.
c. Use the lowest output setting possible to make a good quality cut at the desired cut speed.
d. Minimize dross buildup on the nozzle tip by starting the cut from the edge of the plate when possible.
e. Pierce cutting should be done only when necessary. If piercing, angle the torch about 30° from the plane perpendicular to the workpiece, transfer the arc, then bring the torch perpendicular to the work and begin parallel movement.
f. Reduce the number of pilot arc starts without transferring to the work.
g. Reduce the pilot arc time before transferring to the work.
h. Set air pressure to recommended setting. A higher or lower pressure will cause turbulence in the plasma arc, eroding the orifice of the nozzle tip.
i. Use only Lincoln consumable parts. These parts are patented. Using any other replacement consumables may cause damage to the torch or reduce cut quality.
PRO-CUT 80
B-9
OPERATION
MACHINE INTERFACE
The PRO-CUT 80 comes standard with a machine interface. Interface signals provided include: arc start, arc initiated, and arc voltage. These signals are accessible through the 14 pin MS connector on the case front.
ARC START:
The Arc Start circuit allows for triggering of the power source to commence cutting. This circuit can be accessed through pins K and M of the 14 pin MS connector. The circuit has a 17 VDC nominal open circuit voltage and requires a dry contact closure to activate.
ARC INITIATED:
The Arc Initiated circuit provides information as to when a cutting arc has transferred to the work piece.
This circuit can be accessed through pins I and J of the
14 pin MS connector. The circuit provides a dry contact closure when the arc has transferred. Input to this circuit should be limited to 0.3 A for either 120VAC or
30VDC.
ARC VOLTAGE:
The Arc Voltage circuit can be used for activating a torch height control. This circuit can be accessed through pins D and G of the 14 pin MS connector. The circuit provides full electrode to work arc voltage (no voltage divider, 335VDC maximum).
A r c S t a r t K = 2 A
M = 4 A
L
C
D = 3 4 4
E
F
J = 3 4 7
I = 3 4 8
A r c I n i t i a t e d
H
N
G = 3 4 3
A r c V o l t a g e
1 4 - P I N B O X R E C E P T A C L E , F R O N T V I E W
Users wishing to utilize the Machine Interface can order a K867 Universal Adapter (please adhere to the pin locations stated above) or manufacture a 14 pin MS connector cable assembly.
PRO-CUT 80
B-9
B-10
NOTES
B-10
PRO-CUT 80
Section C-1
TABLE OF CONTENTS
- ACCESSORIES -
Accessories ...........................................................................................................................
Section C
Section C-1
PRO-CUT 80
C-2 C-2
ACCESSORIES
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 undercarriage with pull-out handle for machine only. Provides torch and work cable storage.
S22147-043 - Vortech™ nozzle with an .043” (1.2 mm)
Orifice (For 35 - 60 Amps)
S22147-053 - Vortech™ nozzle with an .053” (1.3 mm)
Orifice (For 60 - 85 Amps)
S22147-082 - Vortech TM nozzle with an .082” (2.1 mm)
Orifice (For Gouging at 60 -85 Amps)
S22149 - Electrode - replacement electrodes for cutting.
S22150 - Shield Cup - This shields the torch tip and provides more visibility to the workpiece than the drag cup. Note the shield cup does not prevent the torch tip from touching the workpiece.
S22151 - Drag Cup - The drag cup protects the torch by preventing the torch from touching the workpiece.
K1571 Series - PCT 80 Torches come in 25’ and 50’ lengths in either hand held or mechanized versions.
ALWAYS USE GENUINE LINCOLN ELECTRIC
ELECTRODES AND VORTECH™ NOZZLES
• Only Genuine Lincoln Electric consumables yield the best cutting performance for the PRO-CUT 80.
• The patent pending VORTECH™ nozzle provides an extra “kick” of swirl as the arc exits the nozzle, which improves cutting performance. No other nozzle has this capability or can match its performance.
PRO-CUT 80
Section D-1
TABLE OF CONTENTS
-MAINTENANCE-
Maintenance .........................................................................................................................
Section D
Section D-1
PRO-CUT 80
D-2 D-2
MAINTENANCE
WARNING
ELECTRIC SHOCK
can kill.
• Have an electrician install and service this equipment.
• Turn the input power off at the fuse box before working on equipment.
• Do not touch electrically hot parts.
• Prior to performing preventative maintenance, perform the following capacitor discharge procedure to avoid electric shock.
INPUT FILTER CAPACITOR
DISCHARGE PROCEDURE
1. Turn off input power or disconnect input power lines.
2. Remove the 5/16 in. hex head screws from the side and top of the machine and remove wrap-around machine cover.
3. Be careful not to make contact with the capacitor terminals that are located on the top and bottom of the Power Board on the right side of the machine.
4. Obtain a high resistance and high wattage resistor
(25-1000 ohms and 25 watts minimum). This resistor is not supplied with machine. NEVER USE A
SHORTING STRAP FOR THIS PROCEDURE.
5. Locate the two capacitor terminals (large hex head cap screws) at the bottom of the Power Board shown in Figure D.1.
6. Use electrically insulated gloves and insulated pliers. Hold the body of the resistor and connect resistor leads across the two capacitor terminals.
Hold the resistor in place for 10 seconds. DO NOT
TOUCH CAPACITOR TERMINALS WITH YOUR
BARE HANDS.
7. Repeat the discharge procedure for the other capacitor.
8. Check voltage across the terminals of all capacitors with a DC voltmeter. Polarity of capacitor terminals is marked on the Power Board above terminals. Voltage should be zero. If any voltage remains, repeat this capacitor discharge procedure.
FIGURE D.1 — LOCATION OF INPUT FILTER CAPACITOR TERMINALS
POWER
BOARD
RIGHT SIDE OF MACHINE
CAPACITOR
TERMINALS
INSULATED
PLIERS
POWER
RESISTOR
INSULATED
GLOVES
PRO-CUT 80
D-3 D-3
MAINTENANCE
ROUTINE MAINTENANCE PERIODIC MAINTENANCE
1. Keep the cutting or gouging area and the area around the machine clean and free of combustible materials. No debris should be allowed to collect which could obstruct air flow to the machine.
2. Every 6 months or so, the machine should be cleaned with a low pressure airstream. Keeping the machine clean will result in cooler operation and
higher reliability. Be sure to clean these areas. SEE
WARNING
ELECTRIC SHOCK can kill.
• Turn off machine at the disconnect switch on the front of the machine before tightening, cleaning or replacing consumables.
- Power, Output and Control printed circuit boards and heat sinks
Change consumables as required.
- Power Switch
1. Thermal Protection
- Main Transformer
- Input Rectifier
3. Examine the sheet metal case for dents or breakage. Repair the case as required. Keep the case in good condition to insure that high voltage parts are protected and correct spacings are maintained. All external sheet metal screws must be in place to insure case strength and electrical ground continuity.
Two thermostats protect the machine from excessive operating temperatures. Excessive temperatures may be caused by a lack of cooling air or by operating the machine beyond the duty cycle and output rating. If excessive operating temperatures should occur, the yellow thermal LED will light and the thermostat will prevent output voltage or current.
4. Check the air regulator filter to be sure it does not become clogged. The air filter on the machine is self draining and will not have to be emptied.
Thermostats are self-resetting once the machine cools sufficiently. If the thermostat shutdown was caused by excessive output or duty cycle and the fan is operating normally, the Power Switch may be left on and the reset should occur within a 15 minute period. If the fan is not turning or the air intake louvers were obstructed, then the power must be switched off and the fan problem or air obstruction must be corrected.
5. Check the filter element every several months to see if it is clogged (weekly in very dirty environments). Replace if necessary by first removing the two screws that attach the filter cage to the back panel assembly, then slide the cage away from the back of the machine and remove. Next, twist the clear filter bowl until it comes off (be careful not to lose the o-ring seated at the top of the bowl threads). Unscrew the filter element and replace with new element. Assemble parts in reverse order as described above.
2. Filter Capacitor Conditioning (PRO-CUT 80, 400-
460 VAC only)
A protection circuit is included to monitor the voltage across filter capacitors C1 and C2. In the event that the capacitor voltage is too high, the protection circuit will prevent output. The protection circuit may prevent output providing all these circumstances are met:
6. Inspect the cable periodically for any slits or puncture marks in the cable jacket. Replace if necessary. Check to make sure that nothing is crushing the cable and blocking the flow of air through the air tube inside. Also, check for kinks in the cable periodically and relieve any so as not to restrict the flow of air to the torch.
a. Machine is connected for 400-460 or
460-575 VAC input.
b. Machine did not have power applied for many months.
c. Machine will not produce output when power is first switched on.
If these circumstances apply, the proper action is to switch the machine on and let it idle for up to 30 minutes. This is required to condition the filter capacitors after an extended storage time. The protection circuit will automatically reset once the capacitor conditioning and resultant voltage levels are acceptable. It may be necessary to turn the power switch off and back on again after this period.
PRO-CUT 80
D-4
Maintenance
FIGURE D.2 – MAJOR COMPONENT LOCATIONS
1. Case Front
2. Base and Case Back
3. Center Panel Assembly
4. Output Board Heatsink
5. Power Board Assembly
6. Case Wraparound
6
D-4
1
4
3
5
2
PRO-CUT 80
Section E-1
TABLE OF CONTENTS
-THEORY OF OPERATION SECTION-
Theory of Operation .............................................................................................................
Section E
Section E-1
FIGURE E.1 – PRO-CUT 80 BLOCK LOGIC DIAGRAM
INPUT
LINE
SWITCH
INPUT
RECTIFIER
S
W
I
T
C
H
N
N
E
C
T
R
E
C
O
"A"
A
D
L
E
AIR
PRESSURE
SWITCH
P
R
O
T
E
C
T
I
O
N
SIGNAL
18/36VAC
THERMOSTATS
OUTPUT
CONTROL
CR 1 & 2
RELAY
DRIVE
SIGNAL
POWER BOARD
CR 1 &2
RELAY
IGBT
CAPACITOR
IGBT
IGBT
CAPACITOR
IGBT
IGBT
GATE
SIGNALS
CURRENT
TRANSFORMER
CONTROL BOARD
R
E
A
D
Y
A
I
R
L
O
W
T
H
E
R
M
A
L
S
A
F
E
T
Y
DISPLAY BOARD
MAIN
TRANSFORMER
TRIGGER & SAFETY
ELECTRODE & TRANSFER
CURRENT FEEDBACK
PILOT ENABLE
ELECTRODE SOLENOID ENABLE
AIR SOLENOID ENABLE
WORK
NOZZLE
ELECTRODE
OUTPUT BOARD
PILOT
TRANSISTOR
CHOKE S
O
L
E
N
O
I
D
T
R
O
D
E
E
L
E
C
TRIGGER & SAFETY
TORCH
CONNECTOR
AIR
SOLENOID
REMOTE
INTERFACE
RECEPTACLE
12VAC
24VAC
AUXILIARY
TRANSFORMER
115VAC
FAN
MOTOR
PRO-CUT 80
E-2
INPUT
LINE
SWITCH
E-2
THEORY OF OPERATION
FIGURE E.2 – INPUT LINE VOLTAGE
INPUT
RECTIFIER
"A"
A
D
L
E
AIR
PRESSURE
SWITCH
T
C
H
S
W
I
N
N
E
C
T
R
E
C
O
E
C
T
I
O
N
P
R
O
T
SIGNAL
18/36VAC
THERMOSTATS
OUTPUT
CONTROL
CR 1 & 2
RELAY
DRIVE
SIGNAL
POWER BOARD
CR 1 &2
RELAY
IGBT
CAPACITOR
IGBT
IGBT
CAPACITOR
IGBT
IGBT
GATE
SIGNALS
CURRENT
TRANSFORMER
CONTROL BOARD
R
E
A
D
Y
L
O
W
A
I
R
M
L
T
H
E
R
S
A
F
E
T
Y
DISPLAY BOARD
MAIN
TRANSFORMER
TRIGGER & SAFETY
ELECTRODE & TRANSFER
CURRENT FEEDBACK
PILOT ENABLE
ELECTRODE SOLENOID ENABLE
AIR SOLENOID ENABLE
WORK
NOZZLE
OUTPUT BOARD
PILOT
TRANSISTOR
ELECTRODE
CHOKE
S
O
L
E
N
O
I
D
T
R
O
D
E
E
L
E
C
TRIGGER & SAFETY
TORCH
CONNECTOR
AIR
SOLENOID
REMOTE
INTERFACE
RECEPTACLE
12VAC
24VAC
AUXILIARY
TRANSFORMER
115VAC
FAN
MOTOR
GENERAL DESCRIPTION
The PRO-CUT 80 is a constant current, continuous control plasma cutting power source. The inverter based power supply design is controlled by a microprocessor control board. The control system has a safety mechanism to insure that the nozzle and electrode are in place before cutting or gouging. The PRO-
CUT 80 initiates the plasma arc with a simple, yet reliable, touch start mechanism. This system eliminates many of the problems associated with hi-frequency type start systems. When powered up, the machine performes some rudimentary self diognostics.
INPUT LINE VOLTAGE, SWITCH
AND MAIN TRANSFORMER
The single-phase or three-phase input power is connected to the machine, via an input line cord, to a switch located on the front panel.
A reconnect panel and voltage range switch allow the user to configure the machine for either a low or high input voltage and also connect the auxiliary transformer for the appropriate input voltage.
The auxiliary transformer develops the appropriate AC voltages to operate the cooling fan, the control board and the plasma output board.
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
PRO-CUT 80
E-3 E-3
THEORY OF OPERATION
INPUT
LINE
SWITCH
INPUT
RECTIFIER
"A"
A
D
L
E
AIR
PRESSURE
SWITCH
T
C
H
S
W
I
N
N
E
C
T
R
E
C
O
E
C
T
I
O
N
P
R
O
T
SIGNAL
18/36VAC
THERMOSTATS
OUTPUT
CONTROL
CR 1 & 2
RELAY
DRIVE
SIGNAL
POWER BOARD
CR 1 &2
RELAY
IGBT
CAPACITOR
IGBT
IGBT
CAPACITOR
IGBT
IGBT
GATE
SIGNALS
CURRENT
TRANSFORMER
CONTROL BOARD
R
E
A
D
Y
A
I
R
L
O
W
T
H
E
R
M
L
S
A
F
E
T
Y
DISPLAY BOARD
MAIN
TRANSFORMER
TRIGGER & SAFETY
ELECTRODE & TRANSFER
CURRENT FEEDBACK
PILOT ENABLE
ELECTRODE SOLENOID ENABLE
AIR SOLENOID ENABLE
WORK
NOZZLE
OUTPUT BOARD
PILOT
TRANSISTOR
ELECTRODE
CHOKE
N
O
I
S
O
L
E
D
T
R
O
D
E
E
L
E
C
TRIGGER & SAFETY
TORCH
CONNECTOR
AIR
SOLENOID
REMOTE
INTERFACE
RECEPTACLE
12VAC
24VAC
AUXILIARY
TRANSFORMER
115VAC
FAN
MOTOR
PRECHARGE AND PROTECTION
The input voltage is rectified by the input rectifier. The resultant DC voltage is applied, through the reconnect switch, to the power board. The power board contains precharging circuitry for the safe charging of the input filter capacitors. Once the capacitors are precharged and balanced the control board activates the CR1+
CR2 input relays. This connects full input power to the filter capacitors. When the filter capacitors are fully charged they act as power supplies for the IGBT switching circuit. The Insulated Gate Bipolar Transistors supply the main transformer primary winding
with DC current flow. See IGBT Operation discussion
and diagrams in this section.
The power board also monitors the filter capacitors for voltage balance and under or overvoltage. If either should occur, the appropriate signal is sent to the control board to deactivate the CR1+ CR2 input relay. The machine output will also be disabled.
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
PRO-CUT 80
E-4 E-4
THEORY OF OPERATION
FIGURE E.4 – MAIN TRANSFORMER
INPUT
LINE
SWITCH
INPUT
RECTIFIER
"A"
A
D
L
E
AIR
PRESSURE
SWITCH
S
W
I
T
C
H
N
N
E
C
T
R
E
C
O
E
C
T
I
O
N
P
R
O
T
SIGNAL
18/36VAC
THERMOSTATS
OUTPUT
CONTROL
CR 1 & 2
RELAY
DRIVE
SIGNAL
POWER BOARD
CR 1 &2
RELAY
IGBT
CAPACITOR
IGBT
IGBT
CAPACITOR
IGBT
IGBT
GATE
SIGNALS
CURRENT
TRANSFORMER
CONTROL BOARD
R
E
A
D
Y
L
O
W
A
I
R
M
A
L
T
H
E
R
S
A
F
E
T
Y
DISPLAY BOARD
MAIN
TRANSFORMER
TRIGGER & SAFETY
ELECTRODE & TRANSFER
CURRENT FEEDBACK
PILOT ENABLE
ELECTRODE SOLENOID ENABLE
AIR SOLENOID ENABLE
WORK
NOZZLE
ELECTRODE
OUTPUT BOARD
PILOT
TRANSISTOR
CHOKE
N
O
I
S
O
L
E
D
T
R
O
D
E
E
L
E
C
TRIGGER & SAFETY
TORCH
CONNECTOR
AIR
SOLENOID
REMOTE
INTERFACE
RECEPTACLE
12VAC
24VAC
AUXILIARY
TRANSFORMER
115VAC
FAN
MOTOR
MAIN TRANSFORMER
Each IGBT pair acts as a switch assembly. Each assembly feeds a separate, oppositely wound primary winding of the main transformer. The reverse direction of current flow through the main transformer primaries and the offset timing of the IGBT pairs induce an AC square wave output signal at the secondary of the main transformer.
The DC current flow through each primary winding is redirected or "clamped" back to each respective filter capacitor when the IGBTs are turned off. This is needed due to the inductance of the transformer primary winding.
The primary currents also pass through the current transformer, which sends a signal to the control board.
If the primary currents are not equal, the control board compensates by adjusting the IGBT gate signals.
The firing of both IGBT pairs occurs during halves of the 50 microsecond intervals, creating a constant
20KHZ output.
The secondary portion of the main transformer is made up of two separate windings. One secondary winding supplies the electrode-to-work voltage. This is the high current winding, which is capable of supplying maximum output current during the cutting process.
The other secondary winding supplies the electrodeto-nozzle voltage for the pilot arc current. The conductor in this winding is smaller since the pilot current is considerably less than the cutting current. While one winding is conducting the other winding is at a limited voltage and aids in the arc transfer to and from the workpiece.
PRO-CUT 80
E-5
INPUT
LINE
SWITCH
INPUT
RECTIFIER
S
W
I
T
C
H
N
N
E
C
T
R
E
C
O
"A"
A
D
L
E
AIR
PRESSURE
SWITCH
P
R
O
T
E
C
T
I
O
N
SIGNAL
18/36VAC
THERMOSTATS
OUTPUT
CONTROL
CR 1 & 2
RELAY
DRIVE
SIGNAL
POWER BOARD
CR 1 &2
RELAY
IGBT
CAPACITOR
IGBT
IGBT
CAPACITOR
IGBT
IGBT
GATE
SIGNALS
CURRENT
TRANSFORMER
CONTROL BOARD
R
E
A
D
Y
A
I
R
L
O
W
T
H
E
R
M
A
L
S
A
F
E
T
Y
DISPLAY BOARD
MAIN
TRANSFORMER
TRIGGER & SAFETY
ELECTRODE & TRANSFER
CURRENT FEEDBACK
PILOT ENABLE
ELECTRODE SOLENOID ENABLE
AIR SOLENOID ENABLE
REMOTE
INTERFACE
RECEPTACLE
E-5
THEORY OF OPERATION
FIGURE E.5 – PLASMA OUTPUT BOARD AND TORCH
WORK
NOZZLE
ELECTRODE
OUTPUT BOARD
PILOT
TRANSISTOR
CHOKE
S
O
L
E
N
O
I
D
T
R
O
D
E
E
L
E
C
TRIGGER & SAFETY
TORCH
CONNECTOR
AIR
SOLENOID
12VAC
24VAC
AUXILIARY
TRANSFORMER
115VAC
FAN
MOTOR
OUTPUT BOARD AND TORCH
The output board contains an Insulated Gate Bipolar
Transistor (IGBT) which, upon receiving a pilot signal from the control board, either enables or disables the current in the pilot winding. The cutting and pilot rectifier diodes are also incorporated in the output board. There are two diodes for the pilot winding and four diodes for the cutting winding.
There are two P.C. board mounted current sensors. One sensor regulates pilot and cutting current. The other sensor indicates to the control board when and how much current transfers to the workpiece.
The output board also includes the trigger circuitry, the gas solenoid driver, the electrode solenoid driver and the torch parts-in-place circuitry and remote interface circutry.
The output choke, which is in series with both the pilot circuit and the cutting circuit, provides current filtering to enhance arc stability.
The PCT 80 torch uses a patented touch start mechanism that provides superior starting performance over other touch start systems. The torch head consists of 3 major parts: torch body, insulator and piston. The insulator provides an electrical barrier between the piston and torch body. The piston provides a path for electrical current to the electrode. The piston also drives the electrode to the nozzle for arc initiation. The torch body contains the main torch components: the trigger, pilot arc, cutting arc, and air flow systems are included.
A copper nozzle with a patented internal swirl is used to focus the arc. A small, precise hole in the end of the nozzle constricts the arc and increases the current density.
As the air enters the torch head, it is directed between the electrode and nozzle for maximum electrode cooling.
A portion of the cooling air exits the chamber through vents in the side of the nozzle. A swirl texture located inside the bottom of the nozzle increases the plenum air swirl strength, and improves arc start reliability and partsin-place verification.
Plasma arc initiation occurs as follows: First, in the idle state, a spring inside the torch head pushes the piston and electrode forward to make continuity with the nozzle.
When the trigger is pulled, air flow begins and creates enough back force on the electrode to overcome the force of the spring. However, the solenoid valve allows enough forward force on the piston to maintain continuity between the consumables. After this continuity has been verified by the Pro-Cut’s parts-in-place circuit, output current is established and regulated. Once the current stabilizes, the solenoid valve turns off, removing the forward force on the piston. The back pressure drives the piston and electrode away from the nozzle, creating the plasma arc. The air stream forces the arc out the orifice of the nozzle. This appears as a pilot arc, which can then be transferred for cutting.
PRO-CUT 80
E-6 E-6
THEORY OF OPERATION
FIGURE E.6 – CONTROL AND DISPLAY BOARDS
INPUT
LINE
SWITCH
INPUT
RECTIFIER
"A"
A
D
L
E
AIR
PRESSURE
SWITCH
T
C
H
S
W
I
N
N
E
C
T
R
E
C
O
E
C
T
I
O
N
P
R
O
T
SIGNAL
18/36VAC
THERMOSTATS
OUTPUT
CONTROL
CR 1 & 2
RELAY
DRIVE
SIGNAL
POWER BOARD
CR 1 &2
RELAY
IGBT
CAPACITOR
IGBT
IGBT
CAPACITOR
IGBT
IGBT
GATE
SIGNALS
CURRENT
TRANSFORMER
CONTROL BOARD
R
E
A
D
Y
A
I
R
L
O
W
T
H
E
R
M
L
S
A
F
E
T
Y
DISPLAY BOARD
MAIN
TRANSFORMER
TRIGGER & SAFETY
ELECTRODE & TRANSFER
CURRENT FEEDBACK
PILOT ENABLE
ELECTRODE SOLENOID ENABLE
AIR SOLENOID ENABLE
WORK
NOZZLE
OUTPUT BOARD
PILOT
TRANSISTOR
ELECTRODE
CHOKE
N
O
I
S
O
L
E
D
T
R
O
D
E
E
L
E
C
TRIGGER & SAFETY
TORCH
CONNECTOR
AIR
SOLENOID
REMOTE
INTERFACE
RECEPTACLE
12VAC
24VAC
AUXILIARY
TRANSFORMER
115VAC
FAN
MOTOR
CONTROL AND DISPLAY BOARDS
The control board receives status and analog feedback signals from the output board, display board, power board and various sensors. The processor interprets these signals, makes decisions and changes machine mode and output to satisfy the requirements as defined by the internal software. The control board regulates the output of the machine by controlling the
IGBT switching times through pulse width modulation
circuitry. See Pulse Width Modulation in this section.
The display board receives commands from the control board and, via indicator lights, communicates
PRO-CUT 80 status and operating conditions to the user.
PRO-CUT 80
E-7 E-7
THEORY OF OPERATION
PROTECTION CIRCUITS
Protection circuits are designed into the PRO-CUT 80 machine to sense trouble and shut down the machine before the trouble damages internal machine components. Both overload and thermal protection circuits are included.
OVERLOAD PROTECTION
The PRO-CUT 80 is electrically protected from producing higher than normal output currents. If the output current exceeds 85-90 amps, an electronic protection circuit limits the current to within the capabilities of the machine.
Another protection circuit monitors the voltage across the input filter capacitors. If the filter capacitor voltage is too high, too low or not balanced the protection circuit may prevent machine output.
THERMAL PROTECTION
Two thermostats protect the machine from excessive operating temperatures. One thermostat is located on the output choke and the other on the power board
IGBT heat sink. Excessive temperatures may be caused by a lack of cooling air or by operating the machine beyond the duty cycle and output rating. If excessive operating temperatures should occur, the thermal status indicator will light and the thermostat will prevent output voltage or current.
Thermostats are self-resetting once the machine cools sufficiently. If the thermostat shutdown was caused by excessive output or duty cycle and the fan is operating normally, the power switch may be left on and the reset should occur within a 15 minute period. If the fan is not turning or the air intake louvers are obstructed, the input power must be removed and the fan problem or air obstruction must be corrected.
PRO-CUT 80
E-8 E-8
THEORY OF OPERATION
INSULATED GATE BIPOLAR
TRANSISTOR (IGBT) OPERATION
An IGBT is a type of transistor. IGBTs are semiconductors well suited for high frequency switching and high current applications.
Drawing A shows an IGBT in a passive mode. There is no gate signal, zero volts relative to the source, and therefore, no current flow. The drain terminal of the
IGBT may be connected to a voltage supply; but since there is no conduction the circuit will not supply current to components connected to the source. The circuit is turned off like a light switch in the OFF position.
Drawing B shows the IGBT in an active mode. When the gate signal, a positive DC voltage relative to the source, is applied to the gate terminal of the IGBT, it is capable of conducting current. A voltage supply connected to the drain terminal will allow the IGBT to conduct and supply current to circuit components coupled to the source. Current will flow through the conducting IGBT to downstream components as long as the positive gate signal is present. This is similar to turning ON a light switch.
n + p n n + p +
SOURCE n +
DRAIN
A. PASSIVE
FIGURE E.7 – CONTROL AND DISPLAY BOARDS
GATE
BODY REGION
DRAIN DRIFT REGION
BUFFER LAYER
INJECTING LAYER n + p n n + p +
SOURCE n +
DRAIN
B. ACTIVE
POSITIVE
VOLTAGE
APPLIED
GATE
BODY REGION
DRAIN DRIFT REGION
BUFFER LAYER
INJECTING LAYER
PRO-CUT 80
E-9 E-9
THEORY OF OPERATION
PULSE WIDTH MODULATION
The term PULSE WIDTH MODULATION describes how much time is devoted to conduction in the positive and negative portions of the cycle. Changing the pulse width is known as MODULATION. Pulse Width
Modulation (PWM) is the varying of the pulse width over the allowed range of a cycle to affect the output of the machine.
MINIMUM OUTPUT
By controlling the duration of the gate signal, the IGBT is turned on and off for different durations during a cycle. The top drawing below shows the minimum output signal possible over a 50-microsecond time period.
The positive portion of the signal represents one IGBT group 1 conducting for 1 microsecond. The negative portion is the other IGBT group 1 . The dwell time (off time) is 48 microseconds (both IGBT groups off).
Since only 2 microseconds of the 50-microsecond time period is devoted to conducting, the output power is minimized.
MAXIMUM OUTPUT
By holding the gate signals on for 22 microseconds each and allowing only 3 microseconds of dwell time
(off time) during the 50-microsecond cycle, the output is maximized. The darkened area under the top curve can be compared to the area under the bottom curve.
The more dark area under the curve, the more power is present.
1 An IGBT group consists of two IGBT modules feeding one transformer primary winding.
FIGURE E.8 – TYPICAL IGBT OUTPUTS sec 48
50 sec sec
MINIMUM OUTPUT sec
22 sec
3 sec
50 sec
MAXIMUM OUTPUT
22 sec
PRO-CUT 80
E-10
NOTES
E-10
PRO-CUT 80
Section F-1
TABLE OF CONTENTS
TROUBLESHOOTING & REPAIR SECTION
Troubleshooting & Repair Section .................................................................................Section F
Test Procedures
Primary Power Board Resistance Test and Capacitor Voltage Test .............................F-15
Replacement Procedures
Primary Power Board and Filter Capacitor Removal and Replacement ......................F-50
Section F-1
PRO-CUT 80
F-2
TROUBLESHOOTING & REPAIR
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and repair should be performed by only Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below.
Step 1. LOCATE PROBLEM (SYMPTOM). Look under the column labeled “PROBLEM (SYMP-
TOMS). This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the symptom that the machine is exhibiting. Symptoms are grouped into four main categories: Output Problems,
Function Problems, Cutting Problems and LED
Function Problems.
Step 3. PERFORM COMPONENT TESTS. The last column, labeled “Recommended Course of
Action” lists the most likely components that may have failed in your machine. It also specifies the appropriate test procedure to verify that the subject component is either good or bad. If there are a number of possible components, check the components in the order listed to eliminate one possibility at a time until you locate the cause of your problem.
Step 2. PERFORM EXTERNAL TESTS.
The second column, labeled “POSSIBLE AREAS OF
MISADJUSTMENT(S)”, lists the obvious external possibilities that may contribute to the machine symptom. Perform these tests/checks in the order listed. In general, these tests can be conducted without removing the case wrap-around cover.
All of the referenced test procedures referred to in the Troubleshooting Guide are described in detail at the end of this chapter. Refer to the
Troubleshooting and Repair Table of Contents to locate each specific Test Procedure. All of the referred to test points, components, terminal strips, etc., can be found on the referenced electrical wiring diagrams and schematics. Refer to the Electrical Diagrams Section Table of Contents to locate the appropriate diagram.
F-2
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353.
PRO-CUT 80
F-3 F-3
TROUBLESHOOTING & REPAIR
PC BOARD TROUBLESHOOTING PROCEDURES
WARNING
ELECTRIC SHOCK can kill.
Have an electrician install and service this equipment. Turn the machine OFF before working on equipment. Do not touch electrically hot parts.
Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections. To avoid problems when troubleshooting and replacing PC boards, please use the following procedure:
1.
Determine to the best of your technical ability that the PC board is the most likely component causing the failure symptom.
2.
Check for loose connections at the PC board to assure that the PC board is properly connected.
3.
If the problem persists, replace the suspect PC board using standard practices to avoid static electrical damage and electrical shock. Read the warning inside the static resistant bag and perform the following procedures:
PC Board can be damaged by static electricity.
ATTENTION
Static-Sensitive
Devices
Handle only at
Static-Safe
Workstations
Reusable
Container
Do Not Destroy
• Remove your body’s static charge before opening the static-shielding bag. Wear an anti-static wrist strap. For safety, use a 1 Meg ohm resistive cord connected to a grounded part of the equipment frame.
• If you don’t have a wrist strap, touch an unpainted, grounded, part of the equipment frame.
Keep touching the frame to prevent static build-up. Be sure not to touch any electrically live parts at the same time.
• Tools which come in contact with the PC Board must be either conductive, anti-static or static-dissipative.
• Remove the PC Board from the static-shielding bag and place it directly into the equipment. Don’t set the PC Board on or near paper, plastic or cloth which could have a static charge. If the PC Board can’t be installed immediately, put it back in the staticshielding bag.
• If the PC Board uses protective shorting jumpers, don’t remove them until installation is complete.
• If you return a PC Board to The Lincoln Electric
Company for credit, it must be in the static-shielding bag. This will prevent further damage and allow proper failure analysis.
4.
Test the machine to determine if the failure symptom has been corrected by the replacement PC board.
NOTE: Allow the machine to heat up so that all electrical components can reach their operating temperature.
5.
Remove the replacement PC board and substitute it with the original PC board to recreate the original problem.
a. If the original problem does not reappear by substituting the original board, then the
PC board was not the problem. Continue to look for bad connections in the control wiring harness, junction blocks, and terminal strips.
b. If the original problem is recreated by the substitution of the original board, then the
PC board was the problem. Reinstall the replacement PC board and test the machine.
6.
Always indicate that this procedure was followed when warranty reports are to be submitted.
NOTE: Following this procedure and writing on the warranty report, “INSTALLED AND SWITCHED
PC BOARDS TO VERIFY PROBLEM,” will help avoid denial of legitimate PC board warranty claims.
PRO-CUT 80
F-4
Observe Safety Guidelines detailed in the beginning of this manual.
F-4
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
OUTPUT PROBLEMS
RECOMMENDED
COURSE OF ACTION
Major physical or electrical damage is evident when the sheet metal cover(s) are removed.
1. Contact your local authorized
Lincoln Electric Field Service
Facility for technical assistance.
1. Contact the Lincoln Electric
Service Department,
1-800-833-9353 (WELD).
Machine is dead – no output – no fan – no status indicator lights.
1. Make sure that the input power switch is in the “ON” position.
2. Check the input voltage at the machine. Input voltage must match the rating plate and the reconnect panel.
3. Check for blown or missing fuses in the input lines and the
0.6 amp slow blow reconnect fuse.
1. Check the input power switch
(S1) for proper operation. See the Wiring Diagram.
2. Check the leads associated with the power switch (S1) and the auxiliary transformer (T2) for loose or faulty connections.
See the Wiring Diagram.
3. Perform the Auxiliary Trans- former Test.
Machine is dead - not output - no status indicator lights - fans run.
1. Check the input voltage at the machine. Input voltage must match the rating plate and the reconnect panel.
3. Perform the Input Rectifier
4. The control board may be faulty. Replace.
5. The display board may be faulty. Replace.
All status indicators remain lit immediately after power up.
1. The microprocessor has experienced a memory fault. Contact your Local Lincoln Authorized
Field Service Facility.
1. The control board may be faulty. Replace.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-800-833-9353.
PRO-CUT 80
F-5
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
F-5
Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
All the status lights begin to blink within 5 seconds of power up.
POSSIBLE AREAS OF
MISADJUSTMENT(S)
FUNCTION PROBLEMS
1. Make sure the PRO-CUT 80 is reconnected correctly for the input voltage being applied. Be sure to remove input power and wait at least one minute before changing the position of the input voltage range switch.
RECOMMENDED
COURSE OF ACTION
2. Perform the Input Rectifier
3. The control board may be faulty. Replace.
4. The primary power board may be faulty. Replace.
The machine powers up properly, but there is no response when the gun trigger is pulled. Only the power LED is lit.
1. Make sure the torch is connected properly to the PRO-CUT 80 machine.
2. Make sure the air supply is connected and operating properly.
3. Make sure the torch head consumable parts are in place and in good condition. Replace if necessary.
1. Perform the Auxiliary Trans- former Test.
2. Perform the Trigger Circuit
4. Perform the Torch Continuity and Solenoid Test.
5. The control board may be faulty. Replace.
6. The output power board may
When the torch trigger is pulled, air begins to flow; but no pilot arc is established.
1. Make sure the torch consumables are in place and in good condition. Replace if necessary.
2. Make sure the air pressure is set at 70 psi (448 kPa.)
3. Make sure there are no kinks or restrictions for air flow in the torch cable.
1. Perform the Torch Continuity and Solenoid Test.
3. The output board may be faulty.
4. The control board may be faulty. Replace.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed.
Call 1-800-833-9353.
PRO-CUT 80
F-6
Observe Safety Guidelines detailed in the beginning of this manual.
F-6
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
FUNCTION PROBLEMS
RECOMMENDED
COURSE OF ACTION
The air begins to flow when the torch trigger is pulled. There is a very brief pilot arc. (Normal is 3 seconds.) The sequence is repeated with subsequent trigger pulls.
1. Make sure the air pressure is set at 70 psi (448 kPa.)
2. Make sure the torch consumables are in place and in good condition.
3. Make sure the air flow is not restricted.
1. Perform the Torch Continuity and Solenoid Test.
2. The output board may be faulty.
Replace.
3. The control board may be faulty. Replace.
The cutting arc starts but sputters badly.
1. Make sure the operating procedure is correct for the process.
this manual.
2. Make sure the work clamp is connected tightly to the workpiece.
3. Make sure the torch consumables are in place and in good condition.
4. Make sure the air supply is not contaminated with oil or excessive water.
5. Make sure the air pressure is set at 70 psi (448 kPa.)
1. Perform the Torch Continuity and Solenoid Test.
2. The output board may be faulty.
Replace.
3. The control board may be faulty. Replace.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-800-833-9353.
PRO-CUT 80
F-7
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
F-7
Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
The pilot arc is normal, but the arc will not transfer to the workpiece.
POSSIBLE AREAS OF
MISADJUSTMENT(S)
CUTTING PROBLEMS
RECOMMENDED
COURSE OF ACTION
1. Make sure the operating procedure is correct for the process.
this manual.
2. Make sure the work clamp is connected tightly to the workpiece.
3. The workpiece must be electrically conductive material.
1. Check the lead connections X2,
X4 and B21 at the output board.
2. Check the output control potentiometer (R1). Normal resistance is 10 ohms. Also check the associated leads for loose or faulty connections to the display board. See the
Wiring Diagram.
3. Check leads #216, #218 and
#219 between the display board and the control board.
Check for loose or faulty connections. See the Wiring
Diagram.
4. The control board may be faulty. Replace.
5. The output board may be faulty.
6. The display board may be faulty. Replace.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed.
Call 1-800-833-9353.
PRO-CUT 80
F-8
Observe Safety Guidelines detailed in the beginning of this manual.
F-8
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
PROBLEMS
(SYMPTOMS)
The Air Low LED is lit.
The Safety LED is flashing.
The Safety LED is lit and steady.
POSSIBLE AREAS OF
MISADJUSTMENT(S)
LED FUNCTION PROBLEMS
RECOMMENDED
COURSE OF ACTION
1. Make sure there is at least 70 psi (448 kPa) of air pressure connected to the gas connection at the back of the PRO-
CUT 80.
2. Press the purge button and set the regulator to 70 psi (448 kPa). Do not reset the air pressure while the air is off (not flowing).
1. The pressure switch (S5) or associated leads may be faulty.
See the Wiring Diagram.
2. The control board may be faulty.
Replace.
1. Make sure there is a Lincoln
PCT 80 torch connected properly to the PRO-CUT 80.
2. Make sure the torch consumables are in place and in good condition.
1. Press the reset button. If the torch and consumables are properly installed, the Safety
LED should turn off.
1. Perform the Torch Continuity and Solenoid Test.
2. Check leads “N”, “E”, #364, and
#369 between the torch receptacle, the output board, and the
Transformer. (See the Wiring
Diagram)
3. The output board may be faulty.
Replace.
1. The reset button or associated wiring may be faulty. See the
Wiring Diagram.
2. Perform the Torch Continuity and Solenoid Test.
3. The control board may be faulty.
Replace.
4. If the machine operates normally with the Safety LED on, the display board may be faulty.
Replace.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed.
Call 1-800-833-9353.
PRO-CUT 80
F-9
Observe Safety Guidelines detailed in the beginning of this manual.
F-9
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
PROBLEMS
(SYMPTOMS)
The Thermal LED is lit.
POSSIBLE AREAS OF
MISADJUSTMENT(S)
LED FUNCTION PROBLEMS
RECOMMENDED
COURSE OF ACTION
1. One of the machine’s thermostats has tripped. Do not turn the PRO-CUT 80 off. Allow the machine to cool. The thermostat(s) will reset themselves.
Either the duty cycle has been exceeded, the fan is not functioning or the louvers are blocked.
1. A thermostat may be faulty.
Replace.
2. The control board may be faulty. Replace.
3. If the machine operates normally with the Thermal LED lit, the display board may be faulty.
Replace.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed.
Call 1-800-833-9353.
PRO-CUT 80
F-10
TROUBLESHOOTING & REPAIR
INPUT FILTER CAPACITOR DISCHARGE PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
F-10
DESCRIPTION
This procedure will drain off any charge stored in the two large capacitors that are part of the power board assembly. This procedure MUST be performed, as a safety precaution, before conducting any test or repair procedure that requires you to touch internal components of the machine.
MATERIALS NEEDED
Volt/Ohmmeter (Multimeter)
5/16” Nut driver
Insulated gloves
Insulated pliers
High wattage resistor - 25 to 1000 ohms, 25 watts minimum
This procedure takes approximately 10 minutes to perform.
PRO-CUT 80
F-11 F-11
TROUBLESHOOTING & REPAIR
INPUT FILTER CAPACITOR DISCHARGE PROCEDURE (continued)
WARNING
ELECTRIC SHOCK can kill.
• Have an electrician install and service this equipment.
• Turn the input power off at the fuse box before working on equipment.
4. Obtain a high resistance and high wattage resistor (25-1000 ohms and 25 watts minimum). This resistor is not supplied with machine. NEVER USE A SHORTING STRAP
FOR THIS PROCEDURE.
5. Locate the four capacitor terminals (large hex head cap screws) shown in Figure F.1.
At the bottom of the PowerBoard
(203,206)(207,202)
• Prior to performing preventative maintenance, perform the following capacitor discharge procedure to avoid electric shock.
DISCHARGE PROCEDURE
1. Turn off input power and disconnect input power lines.
2. Remove the 5/16" hex head screws from the wraparound machine cover.
3. Be careful not to make contact with the capacitor terminals located at the bottom of the Input Power Board.
6. Use electrically insulated gloves and insulated pliers. Hold the body of the resistor and connect the resistor leads across the two capacitor terminals. Hold the resistor in place for 10 seconds. DO NOT TOUCH
CAPACITOR TERMINALS WITH YOUR
BARE HANDS.
7.
Repeat the discharge procedure for the capacitor on the other two terminals.
8.
Check the voltage across the terminals of all capacitors with a DC voltmeter. Polarity of the capacitor terminals is marked on the
PC board above the terminals. Voltage should be zero. If any voltage remains, repeat this capacitor discharge procedure.
FIGURE F.1 – LOCATION OF INPUT FILTER CAPACITOR TERMINALS
POWER
BOARD
RIGHT SIDE OF MACHINE
CAPACITOR
TERMINALS
INSULATED
PLIERS
POWER
RESISTOR
INSULATED
GLOVES
PRO-CUT 80
F-12
TROUBLESHOOTING & REPAIR
INPUT RECTIFIER TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
F-12
DESCRIPTION
This test will help determine if the input rectifier has “shorted” or “open” diodes.
MATERIALS NEEDED
Analog voltmeter/ohmmeter (multimeter)
Phillips head screw driver
Wiring diagram
This procedure takes approximately 15 minutes to perform.
PRO-CUT 80
F-13 F-13
TROUBLESHOOTING & REPAIR
INPUT RECTIFIER TEST (continued)
TEST PROCEDURE
1. Remove main input power to the machine.
2. Perform the Input Filter Capacitor
Discharge Procedure detailed earlier in
this section.
3. Locate the input rectifier (D1) and lead locations. See Figure F.2. Carefully remove the silicone sealant from leads #207, #207A, and #209.
4. With the phillips head screw driver, remove leads #207, 207A and #209 from the rectifier.
5. Use the analog ohmmeter to perform the
tests detailed in Table F.1. See the Wiring
Diagram.
FIGURE F.2 – INPUT RECTIFIER AND LEADS
B
C
#207A
#207
A
TOP VIEW
PRO-CUT 80
#209
F-14
TROUBLESHOOTING & REPAIR
INPUT RECTIFIER TEST (continued)
TABLE F.1 INPUT RECTIFIER TEST POINTS
TEST POINT TERMINALS
+Probe
A
B
C
- Probe
207
207
207
ANALOG METER X10 RANGE
Acceptable Meter Readings
Greater than 1000 ohms
Greater than 1000 ohms
Greater than 1000 ohms
A
B
C
207A
207A
207A
Greater than 1000 ohms
Greater than 1000 ohms
Greater than 1000 ohms
A
B
C
209
209
209
Less than 100 ohms
Less than 100 ohms
Less than 100 ohms
207
207
207
A
B
C
Less than 100 ohms
Less than 100 ohms
Less than 100 ohms
207A
207A
207A
A
B
C
Less than 100 ohms
Less than 100 ohms
Less than 100 ohms
209
209
209
A
B
C
Greater than 1000 ohms
Greater than 1000 ohms
Greater than 1000 ohms
F-14
6. If the input rectifier does not meet the acceptable readings outlined in Table F.1, the component may be faulty. Replace.
NOTE: Before replacing the input rectifier (D1) check the input power switch (S1) and
perform the Primary Power Board
Resistance Test. Also check for leaky
or faulty filter capacitors.
7. If the input rectifier is good, be sure to reconnect leads #207, #207A and #209 to the correct terminals and torque to 31 in.-lbs. Apply a coating of Essex D-4-8 insulating compound and Dow Corning 738 Silicone
Sealant.
8. If the input rectifier is faulty, see the Input
Rectifier Bridge Removal & Replacement
procedure. See the Wiring Diagram and
PRO-CUT 80
F-15
TROUBLESHOOTING & REPAIR
PRIMARY POWER BOARD RESISTANCE TEST AND
CAPACITOR VOLTAGE TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
F-15
DESCRIPTION
This test will determine if the primary power board has any “shorted” or “leaky” power diodes or Insulated Gate Bipolar Transistors (IGBTs). Also it will help to indicate any “shorted” input filter capacitors.
MATERIALS NEEDED
Analog voltmeter/ohmmeter (multimeter)
Wiring Diagram
7/16” Wrench
This procedure takes approximately 25 minutes to perform.
PRO-CUT 80
F-16
TROUBLESHOOTING & REPAIR
PRIMARY POWER BOARD RESISTANCE TEST AND
CAPACITOR VOLTAGE TEST (continued)
FIGURE F.3 – PRIMARY POWER BOARD REMOVAL
F-16
Primary power board with input filter capacitors
208
203 206
+
205 201
207 202
+
204
CAPACITOR (C1)
TERMINALS
CAPACITOR (C2)
TERMINALS
TEST PROCEDURE
1.
Remove main input power to the PRO-
CUT 80.
2. Perform the Input Filter Capacitor
Discharge Procedure detailed earlier in
this section.
3. Locate the primary power board and associated lead locations. See Figure F.3.
4. Carefully remove the main transformer primary leads #201, #204, #205 and #208 from the power board.
5. Use the analog ohmmeter to perform the
PRO-CUT 80
F-17
TROUBLESHOOTING & REPAIR
PRIMARY POWER BOARD RESISTANCE TEST AND
CAPACITOR VOLTAGE TEST (continued)
TABLE F.2
PRIMARY POWER BOARD RESISTANCE TEST POINTS
202A
201
205
203A
208
203A
206
208
206
205
TEST POINT TERMINALS
+ Probe - Probe
201
207A
207A
201
204
207A
202A
204
207A
204
204
202A
201
202A
203A
205
203A
208
208
206
205
206
ANALOG METER X10 RANGE
Acceptable Meter Readings
Greater than 1000 ohms
Less than 100 ohms
Greater than 1000 ohms
Less than 100 ohms
Greater than 1000 ohms
Less than 100 ohms
Greater than 1000 ohms
Less than 100 ohms
Greater than 1000 ohms
Less than 100 ohms
Greater than 1000 ohms
Less than 100 ohms
Greater than 1000 ohms
Less than 100 ohms
Greater than 1000 ohms
Less than 100 ohms
F-17
6.
If the power board does not meet the acceptable readings outlined in Table F.2,
the board is faulty. Replace. See Power
NOTE: Complete power board and filter capacitor replacement is recommended.
7. If the power board “passes” the resistance test, the IGBT portion of the board is good.
However, other circuits on the power board may be faulty. These circuits are NOT readily tested or serviceable.
8. Carefully reconnect leads #201, #204, #205, and #208 to their appropriate terminals.
Torque To 75 IN. LBS.
PRO-CUT 80
F-18 F-18
TROUBLESHOOTING & REPAIR
PRIMARY POWER BOARD RESISTANCE TEST AND
CAPACITOR VOLTAGE TEST (continued)
CAPACITOR VOLTAGE TEST
This test will help the technician to determine if the input filter capacitors are being charged equally to the correct voltage levels.
NOTE: This test should only be conducted with the PRO-CUT 80 connected for 400 VAC or above, and with the appropriate input voltage applied.
TEST PROCEDURE
1. Remove main input power to the PRO-CUT
80.
2. Perform the Input Filter Capacitor
Discharge Procedure detailed earlier in
this section.
3. Locate and familiarize yourself with the capacitor test locations on the primary
4. The following tests will be performed with the input power applied to the PRO-CUT
80. BE CAREFUL. ALWAYS REMOVE
THE INPUT POWER AND PERFORM THE
INPUT FILTER CAPACITOR DISCHARGE
PROCEDURE BEFORE TOUCHING ANY
MACHINE COMPONENT.
WARNING
ELECTRIC SHOCK can kill.
• Have an electrician install and service this equipment.
• Turn the input power off at the fuse box before working on equipment.
5. Apply the correct input power† and turn ON the PRO-CUT 80.
† NOTE: This test should only be conducted with the PRO-CUT 80 reconnect switch and “A” jumper configured for
400 VAC and above.
PRO-CUT 80
F-19 F-19
TROUBLESHOOTING & REPAIR
PRIMARY POWER BOARD RESISTANCE TEST AND
CAPACITOR VOLTAGE TEST (continued)
6. Check for the appropriate voltages outlined in Table F.3.
NOTE: Voltages may vary with the input line voltage.
NOTE: If the capacitor voltage is too high
(over 400 VDC) or too low (less than 220
VDC) the control board will deactivate relay
CR1 + CR2. This will prevent output.
7. If the test voltages do not meet the expected values as listed in Table F.3, the capacitors or other components on the power board may be faulty. Replace.
NOTE: If the capacitor voltages are NOT balanced within 20 VDC, the capacitors may need
“conditioning.” See the Maintenance section.
TABLE F.3 - CAPACITOR VOLTAGES
INPUT APPLIED
EXPECTED VOLTS
DC AT CAPACITOR
TERMINALS
460VAC
440VAC
415VAC
380VAC
325VDC
311VDC
293VDC
269VDC
NOTE: If Capacitor C1 is found to be defective, both Capacitors C1 and C2 must be replaced at the same time. The capacitors must be replaced in matched sets.
PRO-CUT 80
F-20
TROUBLESHOOTING & REPAIR
OUTPUT POWER BOARD RESISTANCE TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
F-20
DESCRIPTION
This test will help the technician determine if the output power board is faulty.
MATERIALS NEEDED
5/16” Nut driver
Analog Volt/ohmmeter
7/16” Wrench
This procedure takes approximately 18 minutes to perform.
PRO-CUT 80
F-21
TROUBLESHOOTING & REPAIR
OUTPUT POWER BOARD RESISTANCE TEST (continued)
FIGURE F.4 – OUTPUT POWER BOARD LEAD LOCATIONS
F-21
X4
(B12)
(B21)
J33
X2
(B11)
X20 X40
TEST POINT
D29
J31
G3439 PRO-CUT 80 OUTPUT
+
TEST POINT
D25
LED3
LED5
LED1
LED4
LED2
J34 J32 J30
TEST PROCEDURE
1. Remove input power to the PRO-CUT 80 machine.
2. Perform the Input Filter Capacitor
Discharge Procedure detailed earlier in this
section.
3. Remove the torch assembly from the machine.
4. Carefully remove leads X4, X2, B21, X20, X40 and plugs J33 and J32 from the output power board. See Figure F.4.
5. Using the analog ohmmeter, perform the
resistance checks per Table F.4.
PRO-CUT 80
F-22
TROUBLESHOOTING & REPAIR
OUTPUT POWER BOARD RESISTANCE TEST (continued)
TEST POINTS
TABLE F.4 - OUTPUT POWER BOARD RESISTANCE
CIRCUIT OR
COMPONENT(S)
BEING TESTED
EXPECTED RESISTANCE
Less than
100 ohms
+Probe J33-Pin4 to
–Probe Terminal X2
+Probe Terminal X2 to
–Probe J33-Pin4
+Probe J33-Pin4 to
–Probe Terminal X4
+Probe Terminal X4 to
–Probe J33-Pin4
+Probe D29 Test Point to
–Probe Terminal X20
+Probe Terminal X20 to
–Probe D29 Test Point
+Probe D29 Test Point to
-Probe Terminal X40
+Probe Terminal X40 to
–Probe D29 Test Point
+Probe D29 Test Point to
–Probe J32-Pin14
+Probe J32-Pin14 to
–Probe D29 Test Point
Diode A1 and associated trace
Diode A1 and associated trace
Diode A1 and associated trace
Diode A1 and associated trace
Diode A2 and associated trace
Diode A2 and associated trace
Diode A2 and associated trace
Diode A2 and associated trace
Transistor A2 and associated trace
Transistor A2 and associated trace
Greater than
1000 ohms
Less than
100 ohms
Greater than
1000 ohms
Less than
100 ohms
Greater than
1000 ohms
Less than
100 ohms
Greater than
1000 ohms
Less than
100 ohms
Greater than
1000 ohms
F-22
6. If any of the resistance checks are not correct, the output power board is faulty. Replace. See the
Output Power Board Removal and Replacement
7. If the output power board “passes” the resistance test, the power diode and transistor portion of the board is good. However, other circuits on the power board may be faulty. These circuits are NOT readily tested or serviceable.
8. Carefully reconnect the leads and plugs previously removed. Torque X2, X4, and B21 to 75 IN. LBS.
PRO-CUT 80
F-23
TROUBLESHOOTING & REPAIR
TORCH CONTINUITY AND SOLENOID TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
F-23
DESCRIPTION
This procedure will help the technician determine if the torch cable, consumables and electrode solenoid are functioning properly.
MATERIALS NEEDED
Volt/ohmmeter
12 VDC @ 1 Amp Power Supply
This procedure takes approximately 15 minutes to perform.
PRO-CUT 80
F-24 F-24
TROUBLESHOOTING & REPAIR
TORCH CONTINUITY AND SOLENOID TEST (continued)
FIGURE F.5 - TORCH CONNECTOR - MACHINE END
5
6
4
7
3
8
2
9
1
TEST PROCEDURE
1. Remove input power to the PRO-CUT 80 machine.
2. Remove the torch assembly from the machine.
3. Using the ohmmeter, check the torch resistances per Table F.5.
NOTE: Take the “Pin” test point measurements at the machine end of the torch assembly. See Figure F.5.
TEST
POINTS
Pin 7 to Pin 8
Pin 7 to Torch
Nozzle
Pin 8 to Torch
Nozzle
Pin 1 to Pin 9
Pin 1 to Pin 9
Pin 2 to Pin 3
Pin 7 to Torch
Electrode at machine end of torch
Pin 8 to Torch
Electrode at machine end of torch
TABLE F.5 - TORCH ASSEMBLY RESISTANCES
CIRCUIT(S) BEING
TESTED
EXPECTED
RESISTANCE
Parallel pilot arc leads
One pilot arc lead to nozzle
1.5 ohms maximum
1.0 ohm maximum
One pilot arc lead to nozzle
1.0 ohm maximum
Torch trigger circuit 100K ohms minimum
Torch trigger circuit
Electrode Solenoid
Pilot and Electrode circuit
1.0 ohm maximum
45 to 55 ohms
1.0 ohm maximum
TEST
CONDITIONS
None
Torch consumables in place
Torch consumables in place
Torch trigger NOT pulled (not activated)
Torch trigger pulled
(activated)
None
Torch consumables in place
Pilot and Electrode circuit
1.0 ohm maximum Torch consumables in place
4. If any of the resistance checks are not correct, the torch assembly may be faulty.
Repair or replace.
PRO-CUT 80
5. Carefully apply the 12 VDC supply to the electrode solenoid. (positive to Pin 2 and negative to Pin 3). The electrode solenoid should activate. Listen for the solenoid action in the torch handle. If the solenoid does not activate, it may be faulty. Replace.
F-25
TROUBLESHOOTING & REPAIR
AIR/GAS SOLENOID TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
F-25
DESCRIPTION
This procedure will help the technician determine if the solenoid is functioning properly.
MATERIALS NEEDED
5/16” Nut driver
12 VDC @ 3 amp supply
Volt/ohmmeter
This procedure takes approximately 13 minutes to perform.
PRO-CUT 80
F-26
TROUBLESHOOTING & REPAIR
AIR/GAS SOLENOID TEST (continued)
FIGURE F.6 – AIR SOLENOID
F-26
TEST PROCEDURE
1. Remove input power to the machine.
2. Perform the Input Capacitor Discharge
Procedure detailed earlier in this section.
3. Locate the air solenoid and leads. See Figure
F.6.
4. Carefully remove plug J31 from the output power board. See Figure F.7.
5. Check the coil resistance of the solenoid at plug J31 pin-6 to J31 pin-5. Normal resistance is approximately 20 ohms. If the resistance is abnormal, check the continuity (zero or very low resistance) of leads #366 and
#361 between the solenoid and plug J31.
See the Wiring Diagram. If the leads are good, the solenoid coil may be faulty.
6. Carefully apply the 12 VDC supply to the solenoid leads at plug J31 (positive to J31 pin-6 lead #366 and negative to J31 pin-5 lead #361).
With proper air pressure applied, the solenoid should activate and air should flow.
If the solenoid activates but air does not flow, check for a restriction in the air line.
7. Install plug J31 back into the output power board.
FIGURE F.7 – PLUG J31 LOCATION
G3439 PRO-CUT 80 OUTPUT
+
X4
(B12)
X2
(B11)
TEST POINT
D25
LED3
LED5
(B21)
LED1
LED4
LED2
J33
X20 X40
TEST POINT
D29
J31
PRO-CUT 80
J34 J32 J30
F-27
TROUBLESHOOTING & REPAIR
(T2) AUXILIARY TRANSFORMER TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
F-27
DESCRIPTION
The test will determine if the auxiliary transformer is functional when the correct primary voltage is applied to the primary winding.
MATERIALS NEEDED
Volt/ohmmeter
Machine wiring diagram
5/16” Nut driver
230 VAC isolated power supply
This procedure takes approximately 18 minutes to perform.
PRO-CUT 80
F-28 F-28
TROUBLESHOOTING & REPAIR
(T2) AUXILIARY TRANSFORMER TEST (continued)
AUXILIARY
TRANSFORMER
FIGURE F.8 – T2 AUXILIARY TRANSFORMER
D1
10 PIN
6 1
7 2
8 3
9 4
5
Plug J21
H 2
H 4
H 5
8 PIN
5
7
8 4
1
2
Plug 22
H 3
H 6
PROCEDURE
1. Remove main input power to the PRO-CUT
80 machine.
2. Perform the Input Filter Capacitor
Discharge Procedure detailed earlier in this
section.
3. Locate the auxiliary transformer. See Fig. F.8
4. Locate and disconnect plugs J21 and J22 from the wiring harness. Cut any necessary cable ties. See Figure F.8.
5. Carefully apply the 230 VAC isolated supply to leads H1 located at the D1 input bridge
(see wiring diagram) and H3 (2J22) of the auxiliary transformer.
6. Carefully check for the presence of the following primary and secondary voltages at the appropriate leads at plugs J21 and J22. See
PRO-CUT 80
F-29 F-29
TROUBLESHOOTING & REPAIR
(T2) AUXILIARY TRANSFORMER TEST (continued)
TABLE F.6 - J21 AND J22 VOLTAGES
TEST POINT
H1
H1
H1
TEST POINT
H2 (5J22)
H4 (7J22)
H5 (8J22)
EXPECTED VOLTAGE
200 - 208VAC
380 - 415VAC
440 - 460VAC
Brown (8J21)
Red (2J21)
Blue (9J21)
Blue (4J21)
Brown (3J21)
Red (6J21)
White (5J21)
White (5J21)
12VAC
24VAC
18VAC
18VAC
Yellow (1J21) Yellow (7J21) 115VAC
7. If the correct test voltages are present, the auxiliary transformer is good.
8. If any of the voltages are missing or very low with the proper primary voltage applied, the auxiliary transformer may be faulty.
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 auxiliary transformer. See the Wiring
Diagram.
10. When finished with the test, replace plugs
21 and 22 and the case wraparound.
PRO-CUT 80
F-30
TROUBLESHOOTING & REPAIR
TRIGGER CIRCUIT TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
F-30
DESCRIPTION
The procedure will help the technician determine if there is a problem or “fault” in the internal trigger circuit.
MATERIALS NEEDED
Ohmmeter/voltmeter (multimeter)
5/16” Nut driver
Simplified Trigger Circuit Diagram
This procedure takes approximately 19 minutes to perform.
PRO-CUT 80
F-31
TRIGGER SWITCH
IN TORCH HANDLE
TROUBLESHOOTING & REPAIR
TRIGGER CIRCUIT TEST (continued)
FIGURE F.9 – SIMPLIFIED TRIGGER CIRCUIT DIAGRAM
SIMPLIFIED TRIGGER CIRCUIT
TORCH
RECEPTACLE
9
#4
#2
1
1J31
2J31
OUTPUT BOARD
+17VDC
3J32 #344
D25
14J32 #312
+15VDC
CONTROL BOARD
11J3 S
S
O
R
P
R
O
C
E
12J3
F-31
WARNING
PILOT ARC, CUTTING ARC, AND HIGH VOLT-
AGE MAY BE PRESENT AT THE
TORCH HEAD. Perform this test with the air input removed to avoid a pilot arc at the torch.
PRO-CUT 80
F-32
TROUBLESHOOTING & REPAIR
TRIGGER CIRCUIT TEST (continued)
9. With the torch trigger activated check the voltage at plug J32 pin-3 (lead#354) (positive) to plug J32 pin-14 (lead#312) (negative). Normal is less than 1 VDC. If more than 1 VDC is indicated, the power output board may be faulty. Release (deactivate) the torch trigger and remove input power to the PRO-CUT 80.
10. Perform the Input Filter Capacitor
11. Check the continuity of leads #354 and
#312 between the output board and the
control board. See Figure F.9, the
Simplified Trigger Circuit Diagram, and
12. If all of the above checks are OK, the control board may be faulty. Replace.
F-32
PRO-CUT 80
F-33
TROUBLESHOOTING & REPAIR
TRIGGER CIRCUIT TEST (continued)
FIGURE F.10 - OUTPUT BOARD TRIGGER CIRCUIT TEST POINTS AND LEDS
F-33
X4
(B12)
(B21)
J33
X2
(B11)
X20 X40
TEST POINT
D29
J31
G3439 PRO-CUT 80 OUTPUT
+
TEST POINT
D25
LED3
LED5
LED1
LED4
LED2
J34 J32 J30
PRO-CUT 80 OUTPUT BOARD
LED DEFINITIONS
LED1: (Red) This light indicates that 24 VAC is being supplied to the output board from the auxiliary transformer. It also shows that the 24 VAC is being rectified to approximately 32 VDC. This
DC voltage is used for the "parts-in-place" check for the torch circuit.
LED2: (Red) This light indicates that 12 VAC is being supplied to the output board from the auxiliary transformer. It also shows that the 12 VAC is being rectified to approximately 17 VDC. This
DC voltage is used to power the trigger circuit and solenoid driver circuits incorporated on the output board.
LED3: (Green) This light indicates that the air solenoid driver circuit is functioning. When this
LED is lit, the air solenoid should be activated.
PRO-CUT 80
LED4: (Green) This light indicates that the trigger circuit on the output board has been activated. This LED should be lit when the torch or remote trigger is closed. This trigger circuit, on the output board, then sends a signal to the control board.
LED5: (Green) This light indicates that the electrode solenoid driver circuit is functioning. When this light is lit, the electrode solenoid should be activated. The electrode solenoid should be energized during gas (air) pre-flow time. During pilot and cutting arc periods, the LED should be off. When the arc goes out, the machine enters the post-flow state. Two seconds after the start of post-flow the electrode solenoid is activated a few times. The LED should blink to indicate this activity. The electrode solenoid will then be energized for the duration of post-flow. (The LED should be on.)
F-34
TROUBLESHOOTING & REPAIR
TRIGGER CIRCUIT TEST (continued)
FIGURE F.11 - CONTROL BOARD LEDs
LED2
LED1
LED3
F-34
CONTROL BOARD LED DEFINITIONS
LED1: (Red) This light indicates that 18 VAC is being supplied to the control board from the auxiliary transformer. It also shows that the 18
VAC is being rectified and should be regulated to
+15 VDC. This +15 VDC supply is used to power the circuitry on the control board.
LED2: (Red) This light indicates that the +5.5
VDC is present. This voltage is derived from the
+15 VDC supply. The +5.5 VDC supply is used to power the circuitry on the control board.
LED3: (Red) This light indicates that 18 VAC is being supplied to the control board from the auxiliary transformer. It also shows that the 18
VAC is being rectified and should be regulated to
-15 VDC. This -15 VDC supply is used to power the circuitry on the control board.
PRO-CUT 80
F-35
TROUBLESHOOTING & REPAIR
LOW VOLTAGE CIRCUIT TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
F-35
DESCRIPTION
These voltage checks will help the technician determine if the correct voltages are being applied and processed by the various P.C. boards. Some of the voltage verification test points are not easily accessible. The presence of these voltages can also be confirmed by
LEDs on the various P.C. boards.
MATERIALS NEEDED
5/16” Nut driver
Volt/ohmmeter (multimeter)
This procedure takes approximately 20 minutes to perform.
PRO-CUT 80
F-36 F-36
TROUBLESHOOTING & REPAIR
LOW VOLTAGE CIRCUIT TEST (continued)
FIGURE F.12 - LOW VOLTAGE CIRCUIT DIAGRAM
T2 AUXILIARY
TRANSFORMER
TO H1
"C" TERMINAL
INPUT
RECTIFIER
H1
H2
BROWN
12VAC
BROWN
8
3
24VAC
RED
RED
2
6
#53
3J30
#56
6J30
#51
1J30
#54
4J30
PLASMA
OUTPUT
BOARD
H3
TO
RECONNECT
LEAD "A"
H4
H5
BLUE
18VAC
WHITE
18VAC
BLUE
4
5
9
#61
1J1
=+15VDC
#62
2J1
=-15VDC
CONTROL BOARD
#64
4J1
6J2
9J2
#216
#219
+
+15VDC
15J40
10J40
D
I
S
P
L
A
Y
B
O
A
R
D
PROCEDURE
J21
1. Remove input power to the PRO-CUT 80 machine.
2. Using the 5/16" nutdriver remove the case wraparound cover.
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically hot parts.
3. Apply the correct input power to the machine and carefully check for the following voltages.
4. Check for the presence of approximately 32
VDC on the output board.
a. LED1 should be lit when 32 VDC is present.
See Figure F.13. See Output Board LED
Definitions and Figure F.12, Low Voltage
Circuit Diagram.
b. To verify the presence of 32 VDC, check across capacitor C13. Make certain the voltmeter probes make good contact with
the capacitor leads. See Figure F.13.
5. Check for the presence of 17 VDC on the output board.
a. LED2 should be lit when 17 VDC is present.
See Figure F.13. See Output Board LED
Definitions and Figure F.12, Low Voltage
Circuit Diagram.
b. To verify the presence of 17 VDC, check from plug J31 Pin-6 to diode D25 (anode).
Make certain the voltmeter probes make good contact with pin-
6 and the diode anode lead. It will be necessary to penetrate the silicon sealant.
6. Check for the presence of +15 VDC on the control board.
a. LED1 should be lit when +15 VDC is pre-
Board LED Definitions and Figure F.12,
Low Voltage Circuit Diagram.
7. Check for the presence of -15 VDC on the control board.
a. LED3 should be lit when -15 VDC is pre-
sent. See Figure F.13. See Control Board
LED Definitions and Figure F.12, Low
Voltage Circuit Diagram.
PRO-CUT 80
F-37
TROUBLESHOOTING & REPAIR
8. Check for the presence of +5 VDC on the control board.
a. LED2 should be lit when +5 VDC is pre-
sent. See Figure F.14. See Control Board
LED Definitions and Figure F.12, Low
9. Check for the presence of +15 VDC being applied to the display board from the control board. You may have to remove the display board to check it.
a. +15 VDC should be present at leads
#216(+) to #219(-). See Figure F.15 and
Figure F.12, Low Voltage Circuit
10. If any of the DC supply voltages are incorrect or missing, make certain the correct AC supply voltages are being applied to the P.C.
boards. See Figure F.12, Low Voltage
11. When the test is complete, remove input power and replace the case wraparound cover.
F-37
PRO-CUT 80
F-38
TROUBLESHOOTING & REPAIR
LOW VOLTAGE CIRCUIT TEST (continued)
FIGURE F.13 – OUTBOARD LOW VOLTAGE CIRCUIT TEST POINTS AND LEDs
F-38
X4
(B12)
(B21)
J33
X2
(B11)
X20 X40
TEST POINT
D29
J31
G3439 PRO-CUT 80 OUTPUT
+
TEST POINT
D25
LED3
LED5
LED1
LED4
LED2
J34 J32 J30
PRO-CUT 80 OUTPUT BOARD
LED DEFINITIONS
LED1: (Red) This light indicates that 24 VAC is being supplied to the output board from the auxiliary transformer. It also shows that the 24 VAC is being rectified to approximately 28 VDC. This
DC voltage is used for the "parts-in-place" check for the torch circuit.
LED2: (Red) This light indicates that 12 VAC is being supplied to the output board from the auxiliary transformer. It also shows that the 12 VAC is being rectified to approximately 17 VDC. This
DC voltage is used to power the trigger circuit and solenoid driver circuits incorporated on the output board.
LED3: (Green) This light indicates that the air solenoid driver circuit is functioning. When this
LED is lit, the air solenoid should be activated.
LED4: (Green) This light indicates that the trigger circuit on the output board has been activated. This LED should be lit when the torch or remote trigger is closed. This trigger circuit, on the output board, then sends a signal to the control board.
LED5: (Green) This light indicates that the electrode solenoid driver circuit is functioning. When this light is lit, the electrode solenoid should be activated. The electrode solenoid should be energized during gas (air) pre-flow time. During pilot and cutting arc periods, the LED should be off. When the arc goes out, the machine enters the post-flow state. Two seconds after the start of post-flow the electrode solenoid is activated a few times. The LED should blink to indicate this activity. The electrode solenoid will then be energized for the duration of post-flow. (The LED should be on).
PRO-CUT 80
F-39
TROUBLESHOOTING & REPAIR
LOW VOLTAGE CIRCUIT TEST (continued)
FIGURE F.14 – CONTROL BOARD LEDs
LED2
LED1
LED3
F-39
CONTROL BOARD LED DEFINITIONS
LED1: (Red) This light indicates that 18 VAC is being supplied to the control board from the auxiliary transformer. It also shows that the 18
VAC is being rectified and should be regulated to
+15 VDC. This +15 VDC supply is used to power the circuitry on the control board.
LED2: (Red) This light indicates that the +5.5
VDC is present. This voltage is derived from the
+15 VDC supply. The +5.5 VDC supply is used to power the circuitry on the control board.
LED3: (Red) This light indicates that 18 VAC is being supplied to the control board from the auxiliary transformer. It also shows that the 18
VAC is being rectified and should be regulated to
-15 VDC. This 15 VDC supply is used to power the circuitry on the control board.
FIGURE F.15 – DISPLAY BOARD TEST POINTS
#216
#219
15
J 40
L10721 DISPLAY BOARD
(REAR VIEW)
1
PRO-CUT 80
F-40
TROUBLESHOOTING & REPAIR
CONTROL BOARD REMOVAL AND REPLACEMENT
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
F-40
DESCRIPTION
The following procedure will aid the technician in removing the control board for maintenance or replacement.
MATERIALS NEEDED
5/16” Nut driver
Needle-nose pliers
This procedure takes approximately 15 minutes to perform.
PRO-CUT 80
F-41
TROUBLESHOOTING & REPAIR
CONTROL BOARD REMOVAL AND REPLACEMENT (continued)
FIGURE F.16 - CASE FRONT SCREW REMOVAL
F-41
4 Screws
PROCEDURE
1. Remove input power to the PRO-CUT 80 machine.
2. Remove the wraparound cover and perform
the Input Filter Discharge Procedure
detailed earlier in this section.
3. Using the 5/16” nut driver, remove the four screws holding the front assembly to the top and base of the machine. See Figure F.16.
4. Carefully slide (do not force) the front away from the rest of the machine about one inch.
This will allow more “working” room to remove the control board.
FIGURE F.17 - CONTROL BOARD MOLEX PLUG REMOVAL
CONTROL
BOARD
MOLEX PLUGS (5)
PRO-CUT 80
F-42 F-42
TROUBLESHOOTING & REPAIR
CONTROL BOARD REMOVAL AND REPLACEMENT (continued)
5. Locate the control board and the five molex
type plugs connected to it. See Figure F.17.
6. Carefully remove the five molex type plugs by depressing the locking tabs and gently extracting the plugs from the P.C. board receptacles.
FIGURE F.18 - CONTROL BOARD REMOVAL FROM MOUNTING PINS
DEPRESS
LOCKING TAB ON
MOUNTING PIN
MOUNTING
PIN (8)
CONTROL
BOARD
7. Using the needle-nose pliers and screwdriver, gently remove the control board from the eight mounting pins by depressing the tabs on the mounting pins and carefully removing the board from the pins. See Figure F.18.
CAUTION
Be sure to follow the recommended static-free methods for handling printed circuit boards.
Failure to do so can result in permanent damage to the equipment.
9. Replace the five molex type plugs in their respective receptacles. Be certain they are securely in place.
10. Carefully reposition the front assembly in place and install the four mounting screws previously removed.
11. Inspect, clear and secure all leads before installing the case wrap-around reassembly.
12. Using the 5/16” nut driver, install the case wraparound.
8. When replacing the control board, align the mounting holes with the eight mounting pins and gently slide the P.C. board onto the mounting pins until the board “snaps” onto the pins.
PRO-CUT 80
F-43
TROUBLESHOOTING & REPAIR
DISPLAY BOARD REMOVAL AND REPLACEMENT
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call or 1-800-833-9353 (WELD).
F-43
DESCRIPTION
The following procedure will aid the technician in removing the display board for maintenance or replacement.
MATERIALS NEEDED
5/16” Nut driver
Screw driver
This procedure takes approximately 15 minutes to perform.
PRO-CUT 80
F-44
TROUBLESHOOTING & REPAIR
DISPLAY BOARD REMOVAL & REPLACEMENT (continued)
F-44
FIGURE F.19 - CASE FRONT SCREW REMOVAL
4 Screws
PROCEDURE
1. Remove the input power to the PRO-CUT 80 machine.
2. Remove the wraparound cover and perform
the Input Filter Capacitor Discharge
Procedure detailed earlier in this section.
3. Using the 5/16” nut driver, remove the four screws holding the front assembly to the top and base of the machine. See Figure F.19.
4. Carefully slide (do not force) the front away from the rest of the machine about one inch.
This will allow more “working” room to remove the display board.
PRO-CUT 80
F-45
TROUBLESHOOTING & REPAIR
DISPLAY BOARD REMOVAL & REPLACEMENT (continued)
FIGURE F.20 – DISPLAY BOARD REMOVAL
DISPLAY BOARD
CASE FRONT
F-45
5. Locate the display P.C. board and the one plug connected to it. See Figure F.20.
6. Gently remove the display P.C. board from the three mounting pins.
CAUTION
Be sure to follow the recommended static-free methods for handling printed circuit boards.
Failure to do so can result in permanent damage to the equipment.
7. Depress the locking tab and remove the plug connector from the display board.
8. When replacing the display board, carefully connect the plug into the board. Make certain the plug is secure and the locking tab is in place.
9. Align the display board with the three mounting pins and slide the display board into place.
10. Carefully reposition the front assembly in place and install the four mounting screws previously removed.
11. Inspect, clear and secure all leads in preparation for the case wraparound reassembly.
12. Using the 5/16” nut driver, install the case wraparound.
PRO-CUT 80
F-46
TROUBLESHOOTING & REPAIR
OUTPUT POWER BOARD REMOVAL AND REPLACEMENT
F-46
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
The following procedure will aid the technician in removing the output power board for maintenance or replacement.
MATERIALS NEEDED
5/16” Nut driver
3/16” Allen type wrench
7/16” Wrench
Penetrox A-13 (Lincoln E2529) Electrical Joint Compound
Phillips head screw driver
Torque wrench
This procedure takes approximately 25 minutes to perform.
PRO-CUT 80
F-47
TROUBLESHOOTING & REPAIR
OUTPUT POWER BOARD REMOVAL & REPLACEMENT (continued)
F-47
FIGURE F.21 – OUTPUT POWER BOARD REMOVAL
OUTPUT POWER BOARD
PROCEDURE
1. Remove input power to the PRO-CUT 80 machine.
2. Remove the case wraparound and perform
the Input Capacitor Filter Discharge
Procedure detailed earlier in this section.
3. Locate the output power P.C. board and associated lead and plug connections. See
PRO-CUT 80
F-48
TROUBLESHOOTING & REPAIR
OUTPUT POWER BOARD REMOVAL & REPLACEMENT (continued)
F-48
FIGURE F.22 – OUTPUT BOARD LEAD LOCATIONS
X4
(B12)
(B21)
J33
X2
(B11)
X20 X40
TEST POINT
D29
J31
G3439 PRO-CUT 80 OUTPUT
+
TEST POINT
D25
LED3
LED5
LED1
LED4
LED2
J34 J32 J30
4. Using the 7/16” wrench, remove leads X4, X2 and B21 from the output power board.
5. Remove plugs J30, J31, J32, J33, and J34 from the output power board.
6. Remove leads X20 and X40 from the output power board.
7. Using the phillips head screw driver, remove the four screws from the lower + upper left and right corners of the output power board.
8. Using the 3/16” allen head wrench, remove the four socket screws mounting the output power board to the heat sink.
9. Carefully remove the output power board from the heat sink.
CAUTION
Be sure to follow the recommended static-free methods for handling printed circuit boards.
Failure to do so can result in permanent damage to the equipment.
PRO-CUT 80
F-49
TROUBLESHOOTING & REPAIR
REPLACEMENT PROCEDURE
1. Apply a thin coating of Penetrox A-13
Electrical Joint Compound to the mating surfaces of the output power board and the heat sink. Make sure the surfaces are clean. Do not allow the compound to get into the threaded holes or on the screw threads.
CAUTION
Be sure to follow the recommended static-free methods for handling printed circuit boards.
Failure to do so can result in permanent damage to the equipment.
2. Mount the output power board to the heat sink and pre-torque the four socket head screws to 25 inch-pounds.
3. Finish tightening the four screws to 40-48 inch-pounds.
4. Replace the four phillips head screws previously removed.
5. Replace leads X20 and X40.
6. Replace plugs J30, J31, J32, J33, and J34.
7. Replace leads X4 and X2, then torque to 75
IN. LBS.
8. Replace lead B21 and torque it to 75 IN. LBS.
9. Clear and secure all leads and replace the wraparound cover.
F-49
PRO-CUT 80
F-50
TROUBLESHOOTING & REPAIR
PRIMARY POWER BOARD AND FILTER CAPACITOR
REMOVAL AND REPLACEMENT
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
F-50
DESCRIPTION
The following procedure will aid the technician in removing the primary power board and filter capacitors for maintenance or replacement.
MATERIALS NEEDED
5/16” Nut driver
3/16” Allen type wrench
7/16” Wrench
Phillips Head screw driver
Torque wrench
3/8” Wrench
Penetrox A-13 (Lincoln E2529) Electrical Joint Compound
This procedure takes approximately 40 minutes to perform.
PRO-CUT 80
F-51
TROUBLESHOOTING & REPAIR
PRIMARY POWER BOARD AND FILTER CAPACITOR
REMOVAL AND REPLACEMENT (continued)
FIGURE F.23 – PRIMARY POWER BOARD REMOVAL
F-51
Primary Power
Board With Input
Filter Capacitors
REMOVAL PROCEDURE
1. Remove input power from the PRO-CUT 80 machine.
2. Remove the case wraparound and perform
the Input Filter Capacitor Discharge
Procedure detailed earlier in this section.
3. Locate the primary power board and associated lead and plug connections. See Figure
F.23.
4. Label the leads for reassembly.
5. Remove Plug J10 and any necessary cable ties.
6. Using the 7/16” wrench, remove leads 201,
202, 203, 204, 205, 206, 207, 208 and 209.
PRO-CUT 80
F-52
TROUBLESHOOTING & REPAIR
PRIMARY POWER BOARD AND FILTER CAPACITOR
REMOVAL AND REPLACEMENT (continued)
FIGURE F.24 – POWER BOARD HEATSINK AND CAPACITOR REMOVAL
Heatsink Mounting
Screws (4)
Mounting
Screws (2)
F-52
Socket Head
Screws (8)
7. Using the Phillips Head screw driver, remove the two mounting screws from the top right of the primary power board. See Figure F.24.
8. Using the 3/16” allen type wrench, remove the eight socket head screws and lock washers mounting the primary power board to the heat sink.
9. Carefully remove the primary power board from the heat sink.
CAUTION
Be sure to follow the recommended static-free methods for handling printed circuit boards.
Failure to do so can result in permanent damage to the equipment.
PRO-CUT 80
F-53 F-53
TROUBLESHOOTING & REPAIR
PRIMARY POWER BOARD AND FILTER CAPACITOR
REMOVAL AND REPLACEMENT (continued)
CAPACITOR REMOVAL
1. Using the 3/8” wrench, remove the four screws holding the heat sink to the center panel assembly. Take note of the insulator
placement for reassembly. The four screws have insulating washers on both sides of the panel assembly. These must be properly replaced upon reassembly.
2. Carefully push the heat sink in towards the center of the machine. This is necessary to gain clearance for capacitor(s) removall.
3. Carefully slide the capacitor(s) from the heat sink assembly. Observe polarity markings and terminal position.
CAPACITOR REPLACEMENT AND
P.C. BOARD REPLACEMENT
1. Carefully slide the new capacitor(s) into the heat sink assembly.
2. Reassemble the heat sink assembly to the center panel using the four screws and insu lated washers previously removed. Note insulation placement.
3. Position the capacitors to the P.C.Board for assembly. Note the polarity of the capacitors.
4. Apply a thin coating of Penetrox A-13
Electrical Joint Compound to the mating surfaces of the P.C. board and the heat sink and capacitor terminals.
5. Mount the P.C. board to the heat sink and capacitor assembly. Make sure the capacitor terminals line up with the holes in the P.C.
board and with the correct capacitor polarities.
6. Assemble the eight socket head screws and pre-torque them to 25 inch-pounds.
7. Make certain the capacitors are lined up correctly so that when the capacitor bolts are assembled through the P.C. board, there will
NOT be any distortion to the P.C. board.
8. Finish tightening the eight screws to 40-48 inch-pounds.
9. Assemble the two Phillips Head screws previously removed.
10. Connect the J10 plug.
11. Connect leads 201, 204, 205, 208 and 209 previously removed. Torque to 75 IN. LBS.
12. Connect leads 202A, 207A, 206, and 203A to the capacitor terminals. Torque to 50-60 inch-pounds.
13. Clear and reposition any leads that may be disturbed. Replace wire ties.
14. Replace the case wraparound cover.
PRO-CUT 80
F-54
TROUBLESHOOTING & REPAIR
INPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT
F-54
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
The following procedure will aid the technician in removing the input rectifier bridge for maintenance or replacement.
MATERIALS NEEDED
3/16” Allen type wrench
Phillips head screw driver
Torque wrench
Penetrox A13 (Lincoln E2529) Electrical Joint Compound
Dow Corning 738 (Lincoln E2861) Electrical Insulating Compound
This procedure takes approximately 16 minutes to perform.
PRO-CUT 80
F-55 F-55
TROUBLESHOOTING & REPAIR
INPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued)
PROCEDURE
1. Remove input power to the PRO-CUT 80.
2. Perform the Input Filter Capacitor
Discharge Procedure detailed earlier in this
section.
3. Locate the input rectifier and the leads connected to it. See Figure F.25.
4. Identify and mark the leads connected to the rectifier terminals.
5. With the phillips head screw driver, remove the lead terminals connected to the rectifier terminals.
6. Using the 3/16” allen wrench, remove the two cap head screws and washers mounting the input rectifier bridge to the center panel assembly.
B
C
#207A
#207
A
TOP VIEW
FIGURE F.25 – INPUT RECTIFIER LEAD LOCATIONS
PRO-CUT 80
#209
F-56 F-56
TROUBLESHOOTING & REPAIR
INPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued)
7. Carefully remove the input rectifier bridge.
8. When installing a new input rectifier apply a thin coating of Penetrox A-13 Heat Sink
Compound (Lincoln E2529) to the mating surfaces. Torque the mounting cap screws and nuts to 44 in-lbs.
9. Reconnect the 10 leads to the correct terminals and torque the phillips head screws to 31 in-lbs.
10. Apply Dow Corning 738 Insulating Compound to all six screw heads and terminals. The heavy input lead terminals should be against the rectifier terminals.
11. Assemble case wrap-around cover.
PRO-CUT 80
F-57 F-57
TROUBLESHOOTING & REPAIR
RETEST AFTER REPAIR
Should a machine under test be rejected for any reason requiring the removal of any mechanical part that could affect the machine’s electrical characteristics, or if any electrical components are repaired or replaced, the machine must be retested.
Input Volts/Hertz
208/230/460
INPUT IDLE AMPS AND WATTS
Idle Amps
0.61
Idle Watts
140
Output Current Range
Maximum Open Circuit Voltage
35 - 85 Amps
335 Volts
PRO-CUT 80
F-58
NOTES
F-58
PRO-CUT 80
G-1
ELECTRICAL DIAGRAMS
TABLE OF CONTENTS
-ELECTRICAL DIAGRAMS SECTION-
G-1
ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION G
PRO-CUT 80
G-2
WIRING DIAGRAM - PRO CUT 80
ELECTRICAL DIAGRAMS
G4238 G4239
RIGHT SIDE OF MACHINE
INPUT
PER
N.A.
-
C1
+
FAN
FAN
FAN
MOTOR
FAN
203
208
204
206
POWER
209
205
RELAY
++VOLT
P_XFMR
4 1
5 2
6 3
501
502
503
505
506
507
J10
201
404
207A
203
S4 PRIMARY RECONNECT
203
207A 202
202 207
+
C2
-
3000/450
206
202
X4
XFER
ELEC
XFER
J33
3 1
4 2
R
W
R
W
X2
X40
X20
B21
SHOWN FOR 400-460VAC OPERATION
N.C.
A
200-
208V
206
0.6A
SLOW BLOW
H2
380-
415V
H4
H3
220-
230V
440-
H5
460V
A
J31
1,2 TRIGGER
4 ELECTRODE
3 NOZZLE
5,6 AIR SOL
7,8 ELEC SOL
10 WORK
J32
8 AIR SOL
2 ELEC SOL
3 TRIGGER
13 IGBT
14 GND
J30
1,4 24V
J34
6
7
8
9
10
5
6
7
8
4
5
6
11
12
13
14
8
9
10 3
4
5
6
7
1
2
1
2
3
3
4
1
2
3
4
5
1
2
4
366
369
364
2
360
E
365
2A
4A
361
343
344
347
348
309
310
354
303
312
54
53
51
56
OUTPUT 12V
L1 xxxxxxx
CHOKE
S
401
E
NOTES:
N.A.
1. FOR MACHINES SUPPLIED WITH INPUT CABLE
FOR SINGLE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE.
CONNECT BLACK & WHITE LEADS TO SUPPLY CIRCUIT.
WRAP RED LEAD WITH TAPE TO PROVIDE 600V. INSULATION.
FOR THREE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE.
CONNECT BLACK, RED & WHITE LEADS TO SUPPLY CIRCUIT.
2. FOR MACHINES NOT SUPPLIED WITH INPUT CABLE
FOR SINGLE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES.
CONNECT TERMINALS U & W TO SUPPLY CIRCUIT.
FOR THREE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES.
CONNECT TERMINALS U, V & W TO SUPPLY CIRCUIT.
N.B. SINCE COMPONENTS OR CIRCUITRY OF A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING
THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT
COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER.
N.C. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE.
CONNECTION SHOWN IS FOR 440-460V OPERATION.
N.D. C1 AND C2 CAPACITORS ARE A MATCHED SET.
207A
207
F
-
T3
CURRENT
TRANSFORMER
I
Y Y
201
205
BK-OUT
S
S
3
BK-IN
A
S
X4
I
7
204
208
B
T1
MAIN
XFMR
FR-OUT
S
S
FR-IN
6
2
BK-OUT
X40
X1
X3
W
X30
X10
365
360
N N
S
FR-IN
S
FR-OUT
X20
X2
LEFT SIDE OF MACHINE
OUTPUT
PC BOARD
209
BASE
E
D1
INPUT
D
C
B
CASE FRONT
PROTECTIVE BONDING CIRCUIT
A
A
C
H1
TP1
TP3
B
TP2
A
H1
N
5
H2
12V
N
2
H3
24V
R
H4
R
7
18V
U
8
H5
W
4
H6
18V
U
J22
Y
115V
AUXILIARY
TRANSFORMER
T2
Y
8
3
2
6
9
5
4
1
53
56
51
54
64
62
61
FAN
7
J21
FAN
G W
W
A
V
R
B
277A
U
B
C POWER
S3
PSI_SET
221
S1
277B
223
S2
RESET
503
502
501
507
506
505
312
354
310
309
Y
401
Y
404
W
R
306
W
R
303
302
18V 18V
3
2
1
3
4
2
1
J5
8
6
7
5
J4
5
4
6
P_XFMR
++VOLT
RELAY
CT
TSTAT
3
1
J1
4
2
6
7
8
9
10
2
1
4
3
5
J2
3
2
1
4
5
8
7
6
J3
16
15
14
13
12
11
10
9
7,8 ELEC SHUNT (TWIST PR)
4,5 XFER SHUNT (TWIST PR)
12 GND
11 TRIGGER
3 IGBT
2,6 PSI SWITCH
10 ELEC SOL
9 AIR SOL
210
216
217
218
219
212
213
214
215
CONTROL
275
276
277
277A
R1
10K
2W
CONTROL
POT
CW (MAX)
275
276
223
277
221
216
217
212
218
213
219
214
210
215
15 +15V
14
13
READY LED
LOW_PSI LED
12 POT WIPER
11 RESET
10
7
6
5
9
8
4
3
2
1
J40
GND
THERMAL LED
RESET LED
PSI SET
DISPLAY
A B C D E F G H I
INTERFACE RECEPTACLE
J K L M N
COLOR CODE:
B = BLACK
G = GREEN
R = RED
W = WHITE
U = BLUE
N = BROWN
Y = YELLOW
9
1
1
J3
ELECTRICAL SYMBOLS PER E1537
J40
8
16
J2,J21,J31
1
5
6
E
15
10
5
6
4
306
J20
1
Y
2
302
361
366
4
N
7
3 4
3
J1,J20
J33
1
2
8
N
2
4
W
S5
PRESSURE
R
AIR
SOLENOID
9
1
J4,J10,
J30
1 3
6
4
2
369
364
J5,J22,
J34
1
4
5
8
W
WORK
1
8
J32
7
14
CONNECTOR CAVITY NUMBERING SEQUENCE
(VIEWED FROM COMPONENT SIDE OF BOARD)
XL-RW
L10936
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
G-2
PRO-CUT 80
G-3
SCHEMATIC - CONTROL PC BOARD
ELECTRICAL DIAGRAMS
Vct = 0.01 Ip
MAX
CUTTING
CONTROL
POT
MIN
PURGE
PUSHBUTTON
RESET
PUSHBUTTON
I
D
S
P
L
A
Y
A
R
D
B
O
+15V
CUTTING CURRENT
SETPOINT
...
LOCAL
J2
6
8
J2
9
J2
4.75K
R45
C21
1.0
35V
COM
100K
R47
+5.5V
COM
X10
TCF6000
3
C23
CONTROL_POT
X10
TCF6000
2 /PURGE
5
J2 100
R52
C26
1.0
35V
COM
+5.5V
3
J2 100
R54
C28
1.0
35V
COM
TCF6000
X10
5
/SAFETY_RESET
+5.5V
SHORT = TRIGGER ON
OPEN = TRIGGER OFF
TRIGGER CIRCUIT
OPTOCOUPLER
THERMOSTAT(S)
+15V
1
4
10.0K
R165
R11
332
J4
R12
332
332
R13
R14
R164
10.0K
332
J4
10.0K
R166
R167
221K COM
C13
12
X3
LM224
13
14
SHORT = TEMP OK = H
OPEN = OVERTEMP = L
R17
10.0K
TCF6000
X10
6
COM COM
PSI
PRESSURE SWITCH
2
6
J3
J3
100
R56
+5.5V
C30
1.0
35V
COM
TCF6000
X10
7
/PSI_OK
PRIMARY CAP
OPTOCOUPLER
OUTPUT
BOARD
6
2
1.30K
J5
J5
R158
10.0K
R159
1.21K
5
J3
4
J3
243
R39
243
R38
C15
0.1
50V
COM
C35
C47
243
R34
R37
243
COM
R160
10.0K
C40
COM
1
3
4
2
INPUT
INPUT
V
NULL
EE
COM
CW
50K
COM
C67
1.0
35V
6
7
2
3
4
1
11
/
TACH INPUT
TACH INPUT
IBIAS
NC
NC
Ic
X17
LM2907
NC
14
NC
GND
13
12
ISOURCE
5
IBIAS
V+
10
9
ISINK
8
C70
.0047
50V
+5.5V
COM
TCF6000
X16
7
10.0K
COM
+15V
R189
CW
1K
X6
OP27
NULL
V
CC
8
7
6
OUT
NC
5
10.0K
R93
511
R42
511
R96
C53
COM
C43 150p
50V
2
3
X1
LT1014
R70
47.5K
1
7.68K
R73
R72
1.50K
D14
X16
TCF6000
6
COM
C18
.47
50V
+15V
COM
3.74K
11
J3
+15V
R152
20.0K
D25
R153
100K
C39
10.0K
R154
R155
221K
3
X3
LM224
2
1
TRIGGER ON = H
TRIGGER OFF = L
COM
COM
COM
R15
10.0K
1.00K
R23
3
J4
PRIMARY CURRENT
XFORMER
125:1
6
J4
COM
TCF6000
X10
4
10.0K
R156
+15V
COM
10
9
X2
33074A
9
10
LM224
X3
C11
R25
100K
8
8
COM
26.7
R121
10.0K
R104
TCF6000
X16
3
COM
R60
15.0K
C56
.15
100V
R178
10.0K
COM
26.7
R122
D15
1N4936
D17
1N4936
+5.5V
D16
1N4936
D18
1N4936
Y1
8.000MHz
C52
10p
100V
C46
10p
100V
+5.5V
4.75K
R137
Vdd
X11
S-8054HN
Vss
RES
+5.5V
C38
COM
COM
COM
+5.5V
TRIGGER
THERMOSTAT OK
CONTROL_POT
/PURGE
/SAFETY_RESET
/PSI_OK
PRIMARY VOLTAGE
SENSE_AMPS
/PIP
ELECTRODE_AMPS
/RETRACT_ARC
5
7
8
6
GND
X15
/CLR
VREF
SDI
VDD
CLK
VOUT
MS-001BA
/LD
2
4
3
1
19
18
2
8
7
1
Vss
MODB
/IRQ
/XIRQ
XTAL
EXTAL
10
16
14
47
12
PC1
PC7
PC5
PE2
PC3
13
43
49
15
9
PC0
PC4
PE0
PE3
PC6
45
32
36
40
4
PE1
PA2
PB6
PB2
AS
X5
37
23
24
25
26
PB5
PD3 (MOSI)
PD4 (SCK)
PD5 (CS_D/A)
Vdd
68HC711E9
VRH
R/W
VRL
/RESET
E
PA4
PA5
PA6
PB7
PA7
PB0
PB1
PB3
PB4
PE4
PA1
PA0
PD0
PD1
MODA
PD2 (MISO)
34
20
21
3
22
PC2
PE5
PE6
PE7
PA3
11
46
48
50
31
52
6
51
5
C14
17
30
/OUTPUT
COM
29
AIR_SOLENOID
28
PILOT_SWITCH
35
42
ELECTRODE_SOLENOID
27
PRIMARY_POWER
READY
41
SAFETY
39
AIR_LOW
38
THERMAL
44
33
3
2
X2
33074A
R64
1.00K
1
R48
28.0K
10
9
8
C44
150p
50V
C45
R89
100K 2700p
50V
2.43K
R98
V_PWM
D21
1.0A
30V
COM
C57
1.0
35V
COM
COM
+5.5V
1.50K
R112
3.32K
3
1
Q5
2N4403
2
5.62K
COM
C48
330p
100V
C27
COM
330p
100V
C58
0.1
50V
DZ3
5.1V
1W
100K
R183
C29
1.0
50V
SENSE_AUX
R188
39.2K
+15V
+15V
14
C59
100p
100V
12
X2
33074A
13
C60
.018
50V
C12
.018
50V
COM
V_PWM
C54
1.0
35V
C55
COM
15
4
6
7
8
5
VIN
CS+
COMP
EA-
16
9
CT
EA+
SHUTDOWN
RT
X12
UC2856N
AOUT
BOUT
SYNC
Vc
11
14
10
13
12
GND
VREF
CL SS
CS-
1
2
3
NOTE:
Shutdown Condition:
90 Amps = 0.25V
126 Amps = 0.35V
CW
10K
COM
C42
0.1
50V
C50
4.7
35V
COM
267
R140
R141
267
C61
1.8
20V
DZ1
12V
1W DZ2
12V
1W
Vin + Vc
X13
OUT
GND
INV IN
N.I. IN
1
5
4
3
2
COM
C32
0.1
50V
COM
X14
N.I. IN
OUT
Vin + Vc
INV IN
GND
1
4
5
2
3
COM
C33
0.1
50V
C62
1.0
35V
COM
+15V
825
R102
3.74K
R99
Q1
2N4401
D10
3A
40V
D11
3A
40V
D12
3A
40V
J5
3
J5
7
D13
3A
40V
AIR_SOLENOID
PILOT_SWITCH
ELECTRODE_SOLENOID
3.74K
R58
J3
9
D19
COM
+15V
825
R29
Q2
2N4401
-15V
4.75K
GATE DRIVE
PULSE XFMR
OPTOCOUPLER
AIR SOLENOID
3.74K
R100
D22
J3
3
COM
+15V
825
R91
Q3
2N4401
-15V
4.75K
OPTOCOUPLER
IGBT DRIVE
+15V
PRIMARY_POWER
10.0
R110
R196
10.0
10.0
R111
R197
10.0
6.81K
R109
COM
J3
10
D24
R115
3.32K
R116
3.32K
R117
3.32K
R118
3.32K
4.75K
-15V
D20
G
J5
D
S
Q4
4A
100V
C6
.0047
1400V
J5
5
1
COM
J2
7
OPTOCOUPLER
ELECTRODE SOLENOID
RELAY
COILS
PRE-CHARGE
DISABLE
J2
J2
J2
10
2
4
P
L
A
Y
D
I
S
READY
PIP
B
O
A
R
D
AIR_LOW
THERMAL
12
J3
COM
8
J3
7
J3
R33
243
C16
0.1
50V
R32
243
C36
243
R36
COM
C37
R30
243
COM
POWER
SUPPLY
1
J1
2 1
TO: DISPLAY
BOARD
J2
5 1
TO: OUTPUT
BOARD
J3
8 1
TO: CT &
TSTATS
J4
3 1
TO: POWER
BOARD
J5
4
3 4 6 10 9 16 4 6 5 8
+15V
R192
CW
1K
1
NULL
3
4
2
INPUT
INPUT
V
EE
X4
OP27
NULL
V
CC
OUT
NC
8
7
6
5
R28
3.32K
10.0K
R26
6.19K
R40
6
X1
LT1014
5
CW
10K
7
COM
1.21K
R78
221
R35
C17
13
R79
221K
C22
150p
50V
X1
LT1014
14
12
221
R24
100K
R80
R81
10.0K
TCF6000
X16
4
C31
GAIN = 80.0
1V = 12.50 A
1.30K
COM
1V = 68.07mA
D23
COM
221K
R83
5
X3
LM224
6
C4
.47
50V
7
R84
10.0K
TCF6000
X16
5
COM
COM COM
COM
POWER SUPPLY
AUX XFMR
1
J1
18VAC
CT
18VAC
2
J1
4
J1
TP2
50V
15J
D3
D1
TP1
50V
15J
1.0
R1
5W
D2
C1
3300
50V
SENSE_AUX
D5
IN
LM350
X7
S18647 ASSY
ADJ
OUT
C3
1000
35V
+15V
D4
C7
50
50V
IN
GND
X9
7915
OUT
D7
D6
IN
7805
X8
S18395-13 ASSY
GND
OUT
C71
0.1
50V
C9
27
35V
D8
-15V
NOTE:
SOME OR ALL OF THESE
RESISTORS MAY NOT BE PRESENT
POWER SUPPLY
CALIBRATION
C5
100
50V
+5.5V
D9
COM
C72
0.1
50V
LED1
+15V
1.30K
COM
LED2
+5.5V
475
-15V
1.30K
LED3
+15V +15V +5.5V
7
X6
OP27
4
5
6
X2
33074A
X16
2
7
C68 C69 7 4 C63 C64 4 4 13
C2
COM
C8
X4
OP27
4
X1
LT1014
11
COM
C65 C66
X2
33074A
11
X3
LM224
11
C10
X12
UC2856N
12
C19
4.7
35V
COM
-15V
14
1
16 15
13
J3 J3 J3 J3 J3
3 1 2 5 4 8
J1 J2 J4 J4 J5 J5
NOTES :
N.A. SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE
WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE
NUMBER.
C20
C41
8
X16
TCF6000
1
8
X10
TCF6000
1
Vdd
26
C24 X5
68HC711E9
Vss
1
C25
4.7
35V
COM
COM
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
MACHINE OVERVIEW
CUT
DIODES
CUT
WINDINGS
PILOT
WINDINGS
PILOT
DIODES
+5.5V
9
C34
X17
LM2907
12
7
C51
X15
MS-001BA
5
C49
FILENAME: G3353_1CA
GENERAL INFORMATION
ELECTRICAL SYMBOLS PER E1537
CAPACITORS =
RESISTORS = Ohms (
DIODES = 1A, 400V
MFD .022/50V
1/4W
UNLESS OTHERWISE SPECIFIED)
UNLESS OTHERWISE SPECIFIED)
(UNLESS OTHERWISE SPECIFIED)
REF. DESIGNATORS SKIPPED:
R51,R59,R66,R71,R74,R75,R86,R90,R92,R95,R105,R119,
R143-R146,R150,R151,R161-R163,R168,R169,R185,R186
WORK
TRANSFER
SHUNT
NOZZLE
L1
ELECTRODE
SHUNT
LAST NO. USED
R-
C-
D-
197
72
25
X-
Q-
DZ-
17
5
3
Y-
TP-
1
LED-
2
3
LABELS
SUPPLY VOLTAGE NET
POWER SUPPLY SOURCE POINT
COMMON CONNECTION
FRAME CONNECTION
EARTH GROUND CONNECTION
3-19-99
G
3353
G-3
PRO-CUT 80
G-4
PC BOARD ASSEMBLY - CONTROL BOARD (CODE 10574 ONLY)
ELECTRICAL DIAGRAMS
G-4
5.75
6.00
~.04
LED1
LED3
C3
X8
R3
R2
X7
PRO-CUT 80 CONTROL
C70
C67
LED2
X17
R173
G3443-1
C49
X15
X10
X16
X11
X5
C52
Y1
C46
R136
R61
Q5
R62
R63
R132
R133
R187
C20
C55
C54
X12
R111
R197
R110
R196
J5
C50
C42
8.15
DZ2
C33
R140
DZ1
C32
8.75
9.00
~.04
CAPACITORS = MFD/VOLTS
INDUCTANCE = HENRIES
RESISTANCE = OHMS
ITEM
C1 )
C2,C8,C10,C11,C13,C14,C17 )
R6 )
R7,R190,R191,R193,R194 )
R8 )
R9,R15,R50,R64,R88,R103 )
R113
R10,R42,R96 )
R11,R12,R13,R14 )
R16,R21 )
R17,R23,R26,R27,R61,R62 )
R63,R68,R69,R81,R84,R93
R94,R104,R106,R108,R134
R138,R139,R154,R156,R158
R160,R164,R165,R166,R178
R179,R180,R181,R182
R18 )
R19,R53,R55,R57,R85,R149 )
R157
R20,R22,R110,R111,R124 )
R125,R126,R127,R128,R142
R196,R197
R24,R35 )
R25,R47,R49,R80,R89,R153 )
R183
R28,R112,R115,R116,R117 )
R118,R133
R29,R91,R102 )
R31 )
R40 )
R41,R60,R135,R184 )
R43,R44,R45,R130,R136,R137 )
R170,R171,R172
R48 )
R52,R54,R56 )
R58,R76,R99,R100 )
R65,R129 )
R67,R70,R87,R101 )
R72,R195 )
R73,R107 )
R77,R82,R175,R177 )
R78,R159 )
R79,R83,R155,R167 )
R97 )
R98 )
R109 )
R114 )
R120,R121,R122,R123 )
R131 )
R132 )
R140,R141 )
R152 )
R173 )
R174 )
R176 )
R188 )
R189,R192 )
TP1,TP2 )
X1 )
X2 )
X3 )
C20,C23,C24,C31,C34,C35
C36,C37,C38,C39,C40,C41
C47,C49,C51,C53,C55,C63
C64,C65,C66,C68,C69
C3 )
C4,C18 )
C5 )
C6 )
C7 )
C9 )
C12,C60 )
C15,C16,C32,C33,C42,C58 )
C71,C72
C19,C25,C50 )
C21,C26,C28,C30,C54,C57 )
C62,C67
C22,C43,C44 )
C27,C48 )
C29 )
C45 )
C46,C52 )
C56 )
C59 )
C61 )
C70 )
D1,D2,D3,D4,D5,D6,D7,D8,D9 )
D14,D19,D20,D22,D23,D24
D25
D10,D11,D12,D13 )
D15,D16,D17,D18 )
D21 )
DZ1,DZ2 )
DZ3 )
J1 )
J2 )
J3 )
J4 )
J5 )
LED1,LED2,LED3 )
Q1,Q2,Q3 )
Q4 )
Q5 )
R1 )
R2,R46,R187 )
R3,R30,R32,R33,R34,R36,R37 )
R38,R39
R4 )
R5 )
REQ'D
1 )
30 )
PART NO.
S13490-92 )
S16668-5 )
DESCRIPTION
3300/50
.022/50
1 )
2 )
1 )
1 )
1 )
1 )
2 )
8 )
S13490-121 )
S13490-63 )
S13490-71 )
T11577-52 )
S13490-72 )
S13490-93 )
S13490-126 )
S16668-11 )
3 )
8 )
S13490-25 )
S13490-42 )
3 )
2 )
1 )
1 )
2 )
1 )
1 )
1 )
1 )
16 )
S16668-9 )
S16668-8 )
S13490-135 )
S16668-4 )
S16668-13 )
S13490-108 )
S16668-3 )
S13490-19 )
S16668-10 )
T12199-1 )
1000/35
.47/50
100/50
.0047 or .005/1400
50/50
27/35
.018/50V
.1/50
4.7/35
1.0/35
150pF/100
330pF/100
1.0/50V
2700pF/50
10pF/100
.15/100
100pF/100
1.8/20
4700pF/50
1N4004
1 )
1 )
1 )
3 )
3 )
1 )
1 )
1 )
3 )
9 )
4 )
4 )
1 )
2 )
1 )
1 )
1 )
1 )
1 )
1 )
5 )
1 )
7 )
3 )
4 )
2 )
31 )
S19400-5110 )
S19400-3320 )
S19400-3322 )
S19400-1002 )
T12705-37 )
T12705-34 )
T12705-23 )
T12702-19 )
T12702-52 )
S18248-4 )
S18248-10 )
S18248-16 )
S18248-6 )
S18248-8 )
T13657-2 )
T12704-68 )
T12704-80 )
T12704-69 )
T13165-16 )
S19400-2671 )
S19400-2430 )
S19400-30R1 )
S19400-6190 )
S19400-8251 )
S19400-3921 )
S19400-2001 )
S19400-1001 )
1N5822 SCHOTTKY BARRIER DIODE
1N4936
1N5818
1N4742A
1N4733A
HEADER
HEADER
HEADER
HEADER
HEADER
RED LED
2N4401
HEXFET TRANS. (SS)
2N4403
1.0 OHM, 5W RESISTOR
2.67K 1/4W
243 1/4W
30.1 1/4W
619 1/4W
8.25K 1/4W
3.92K 1/4W
2.0K 1/4W
1K 1/4W
511 1/4W
332 1/4W
33.2K 1/4W
10K 1/4W
3.75
.25
0
0
.25
X9
J1
.85
D5
R188
C29
C1
R189
J3
X6
R48
X1
R18
C44
C45
C31
R24
C17
R35
R73
C18
D14
X4
3.55
R19
R17
X3
J4
R98
D21
R88
R64
R60
X2
R50
R41
C11
J2
Q4
D20
C6
1 )
7 )
12 )
S24073-1 )
S19400-5111 )
S19400-10R0 )
10K,1/2W,TRIMMER
5.11K 1/4W
10 1/4W
2 )
7 )
7 )
3 )
1 )
1 )
4 )
9 )
S19400-2210 )
S19400-1003 )
S19400-3321 )
S19400-8250 )
S19400-1004 )
S19400-6191 )
S19400-1502 )
S19400-4751 )
1 )
1 )
1 )
1 )
4 )
1 )
1 )
2 )
1 )
3 )
4 )
2 )
4 )
2 )
2 )
4 )
2 )
4 )
1 )
1 )
1 )
1 )
1 )
2 )
2 )
1 )
1 )
1 )
S19400-2802 )
S19400-1000 )
S19400-3741 )
S19400-2211 )
S19400-4752 )
S19400-1501 )
S19400-7681 )
S19400-1301 )
S19400-1211 )
S19400-2213 )
S19400-8252 )
S19400-2431 )
S19400-6811 )
S19400-5621 )
S19400-26R7 )
S19400-1212 )
S16296-5 )
S19400-2670 )
S19400-2002 )
T10812-39 )
S19400-6812 )
S19400-4750 )
S19400-3922 )
T10812-68 )
T13640-15 )
S15128-16 )
S15128-18 )
S15128-4 )
221 1/4W
100K 1/4W
3.32K 1/4W
825 1/4W
1M 1/4W
6.19K 1/4W
15K 1/4W
4.75K
28.0K 1/4W
100 1/4W
3.74K 1/4W
2.21K 1/4W
47.5K 1/4W
1.5K 1/4W
7.68K 1/4W
1.3K 1/4W
1.21K 1/4W
221K 1/4W
82.5K 1/4W
2.43K 1/4W
6.81K 1/4W
5.62K 1/4W
26.7 1/4W
12.1K 1/4W
10K TRIMMER
267 1/4W
20K 1/4W
50K 1/2W TRIMMER
68.1K 1/4W
475 1/4W
39.2K 1/4W
1K 1/2W TRIMMER
15J
IC,LT1014,LINEAR INTEGRATED CIRCUIT
IC,33074A,OP-AMP,QUAD,HIGH-PERF
IC,LM224,OP-AMP
G
3-19-99
3443-1B3
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 provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.
PRO-CUT 80
G-5
ELECTRICAL DIAGRAMS
PC BOARD ASSEMBLY - CONTROL BOARD (CODE 10577 & 10578 ONLY)
5.75
3.75
.25
N.F.
6.00
0
~.04
0
N.A.
.25
LED1
LED3
X9
C3
J1
X8
.85
R3
R2
D5
R188
C29
C1
X7
R189
J3
X6
R48
X1
3.55
R18
X4
N.F.
PRO-CUT 80 CONTROL
C70
C67
LED2
X17
R173
C44
C45
C31
R24
C17
R35
R73
C18
D14
N.E.
R19
R17
X3
J4
G3560-1
X10
X16
R98
D21
R88
R64
R60
X2
C49
X15
R50
R41
C11
N.G.
J2
X11
X5
Q4
D20
C6
C52
Y1
C46
R136
R61
Q5
R62
R63
R111
R197
J5
2
X12
C50
C42
8.15
R132
R133
R187
C20
C55
C54
DZ2
C33
R110
R196
N.C.
R140
DZ1
C32
8.75
9.00
~.04
THIS SHEET CONTAINS PROPRIETARY INFORMATION
OWNED BY THE LINCOLN ELECTRIC CO.
AND IS
NOT TO BE REPRODUCED, DISCLOSED OR USED
WITHOUT THE EXPRESS PERMISSION OF
THE LINCOLN ELECTRIC CO.
1
N.F.
3
CAPACITORS = MFD/VOLTS
INDUCTANCE = HENRIES
RESISTANCE = OHMS
UNLESS OTHERWISE SPECIFIED TOLERANCE
ON HOLE SIZES PER E2056
ON 2 PLACE DECIMALS IS .02
ON 3 PLACE DECIMALS IS .002
ON ALL ANGLES IS .5 OF A DEGREE
MATERIAL TOLERANCE (" ") TO AGREE
WITH PUBLISHED STANDARDS.
Ch'ge. Sht. No.
XA
3-19-99A
3
3
ITEM
!%ÏG
REQ'D PART NO.
C1 1 S13490-92 3300/50
C2,C8,C10,C11,C13,C14,C17 30 S16668-5 .022/50
C20,C23,C24,C31,C34,C35
C36,C37,C38,C39,C40,C41
C47,C49,C51,C53,C55,C63
C64,C65,C66,C68,C69
C3 1 S13490-121 1000/35
C4,C18 2 S13490-63 .47/50
C5 1 S13490-71 100/50
C6 1 T11577-52 .0047 or .005/1400
C7 1 S13490-72 50/50
C9 1 S13490-93 27/35
C12,C60 2 S13490-126 .018/50V
C15,C16,C32,C33,C42,C58 8 S16668-11 .1/50
C71,C72
C19,C25,C50 3 S13490-25 4.7/35
C21,C26,C28,C30,C54,C57 8 S13490-42 1.0/35
C62,C67
C22,C43,C44 3 S16668-9 150pF/100
C27,C48 2 S16668-8 330pF/100
C29 1 S13490-135 1.0/50V
C45 1 S16668-4 2700pF/50
C46,C52 2 S16668-13 10pF/100
C56 1 S13490-108 .15/100
C59 1 S16668-3 100pF/100
C61 1 S13490-19 1.8/20
C70 1 S16668-10 4700pF/50
D1,D2,D3,D4,D5,D6,D7,D8,D9 16 T12199-1 1N4004
D14,D19,D20,D22,D23,D24
D25
D10,D11,D12,D13 4 T12705-37 1N5822 SCHOTTKY BARRIER DIODE
D15,D16,D17,D18 4 T12705-34 1N4936
D21 1 T12705-23 1N5818
DZ1,DZ2 2 T12702-19 1N4742A
DZ3 1 T12702-52 1N4733A
J1 1 S18248-4 HEADER
J2 1 S18248-10 HEADER
J3 1 S18248-16 HEADER
J4 1 S18248-6 HEADER
J5 1 S18248-8 HEADER
LED1,LED2,LED3 3 T13657-2 RED LED
Q1,Q2,Q3 3 T12704-68 2N4401
Q4 1 T12704-80 HEXFET TRANS. (SS)
Q5 1 T12704-69 2N4403
R1 1 T13165-16 1.0 OHM, 5W RESISTOR
R2,R46,R187 3 S19400-2671 2.67K 1/4W
R3,R30,R32,R33,R34,R36,R37 9 S19400-2430 243 1/4W
R38,R39
R4 1 S19400-30R1 30.1 1/4W
R5 1 S19400-6190 619 1/4W
R6 1 S19400-8251 8.25K 1/4W
R7,R190,R191,R193,R194 5 S19400-3921 3.92K 1/4W
R8 1 S19400-2001 2.0K 1/4W
R9,R15,R50,R64,R88,R103 7 S19400-1001 1K 1/4W
R113
R10,R42,R96 3 S19400-5110 511 1/4W
R11,R12,R13,R14 4 S19400-3320 332 1/4W
R16,R21 2 S19400-3322 33.2K 1/4W
R17,R23,R26,R27,R61,R62 31 S19400-1002 10K 1/4W
R63,R68,R69,R81,R84,R93
R94,R104,R106,R108,R134
R138,R139,R154,R156,R158
R160,R164,R165,R166,R178
R179,R180,R181,R182
R18 1 S24073-1 10K,1/2W,TRIMMER
R19,R53,R55,R57,R85,R149 7 S19400-5111 5.11K 1/4W
R157
R20,R22,R110,R111,R124 12 S19400-10R0 10 1/4W
R125,R126,R127,R128,R142
R196,R197
R24,R35 2 S19400-2210 221 1/4W
R25,R47,R49,R80,R89,R153 7 S19400-1003 100K 1/4W
R183
R28,R112,R115,R116,R117 7 S19400-3321 3.32K 1/4W
R118,R133
R29,R91,R102 3 S19400-8250 825 1/4W
R31 1 S19400-1004 1M 1/4W
R40 1 S19400-6191 6.19K 1/4W
R41,R60,R135,R184 4 S19400-1502 15K 1/4W
R43,R44,R45,R130,R136,R137 9 S19400-4751 4.75K
R170,R171,R172
R48 1 S19400-2802 28.0K 1/4W
R52,R54,R56 3 S19400-1000 100 1/4W
R58,R76,R99,R100 4 S19400-3741 3.74K 1/4W
R65,R129 2 S19400-2211 2.21K 1/4W
R67,R70,R87,R101 4 S19400-4752 47.5K 1/4W
R72,R195 2 S19400-1501 1.5K 1/4W
R73,R107 2 S19400-7681 7.68K 1/4W
R77,R82,R175,R177 4 S19400-1301 1.3K 1/4W
R78,R159 2 S19400-1211 1.21K 1/4W
R79,R83,R155,R167 4 S19400-2213 221K 1/4W
R97 1 S19400-8252 82.5K 1/4W
R98 1 S19400-2431 2.43K 1/4W
R109 1 S19400-6811 6.81K 1/4W
R114 1 S19400-5621 5.62K 1/4W
R120,R121,R122,R123 4 S19400-26R7 26.7 1/4W
R131 1 S19400-1212 12.1K 1/4W
R132 1 S16296-5 10K TRIMMER
R140,R141 2 S19400-2670 267 1/4W
R152 1 S19400-2002 20K 1/4W
R173 1 T10812-39 50K 1/2W TRIMMER
R174 1 S19400-6812 68.1K 1/4W
R176 1 S19400-4750 475 1/4W
R188 1 S19400-3922 39.2K 1/4W
R189,R192 2 T10812-68 1K 1/2W TRIMMER
TP1,TP2 2 T13640-15 15J
X1 1 S15128-16 IC,LT1014,LINEAR INTEGRATED CIRCUIT
X2 1 S15128-18 IC,33074A,OP-AMP,QUAD,HIGH-PERF
X3 1 S15128-4 IC,LM224,OP-AMP
DESCRIPTION
THE LINCOLN ELECTRIC CO.
CLEVELAND, OHIO U.S.A.
DR DRS
SCALE FULL
DATE 2-9-99 CHK
EQUIP.
TYPE
INVERTER WELDERS
SUBJECT
CONTROL P.C. BD AS'BLY (CANADIAN)
REF.
G3443-1
SUP'S'D'G
SHT.
NO.
G
3560-1B3
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 provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.
G-5
PRO-CUT 80
G-6
SCHEMATIC - POWER PC BOARD
C8
+15V
4
X1
LM224
11
C19
+15V
4
X3
LM224
11
4
6
4
6
CR2
3
CR2
5
CR1
3
CR1
5
209
B209
R1
40
10W
R2
40
10W
POSITIVE
INPUT RECTIFIER
R23
150K
R24
150K
40
10W
R4
40
10W
Q1
4A
900V
R25
150K
CAPACITOR
PRECHARGE
R27
DZ7
12V
1W
100
OCI1
CNY17-3V
5
150K
4 6 2
1
1.00K
R33
RECONNECT
206
T1
6
J10
3
J10
DRIVE
12
1
FROM
CONTROL
BOARD
(PWM DRIVE)
8
3
5
G1
GATE
S1
10
4
G2
GATE
S2
S3
GATE
9 G3
6
S4
GATE
7 G4
TEST E
6.2V
1W
R14
10.0
DZ4
TEST D
DZ5
15V
1W
DZ6
15V
1W
1.00K
1.00K
1.00K
1.00K
C3
.0047
50V
R19
10.0
R20
10.0
R21
10.0
R22
10.0
G1
G2
G3
G4
C4 C3 C2 C1
A2
E4 E3 E2 E1
C1
D2
1A
1000V
A1
C1
A1
A2
R80
1K
5W
C22
.022
2000V
C4
.022
2000V
B205
TRANSFORMER
PRIMARY
205
206
C26
.22
1000V
C27
.22
1000V
325VDC
(NOMINAL)
FILTER
CAPACITOR
203
B208
TRANSFORMER
PRIMARY
208
R81
1K
5W
R13
10.0
DZ2
6.2V
1W
DZ3
15V
1W
DZ1
15V
1W
TEST C
1.00K
1.00K
1.00K
1.00K
C2
.0047
50V
10.0
R9
10.0
R10
10.0
R11
10.0
R12
G1
G2
G3
G4
C4 C3 C2 C1
A1
E4 E3 E2 E1
A1
D1
1A
1000V
C23
.022
2000V
C1
.022
2000V
10.0
R63
TEST B
DZ11
6.2V
1W
DZ12
15V
1W
DZ13
15V
1W
1.00K
1.00K
1.00K
1.00K
C11
.0047
50V
10.0
R68
10.0
R69
10.0
R70
10.0
R71
6.2V
1W
R62
10.0
DZ9
TEST A
DZ10
15V
1W
DZ8
15V
1W
1.00K
1.00K
1.00K
1.00K
C10
.0047
50V
10.0
R58
R59
10.0
R60
10.0
R61
10.0
G1
G2
G3
G4
C4 C3 C2 C1
A4
E4 E3 E2 E1
G1
G2
G3
G4
C4 C3 C2 C1
A3
E4 E3 E2 E1
C1
A1
A3
D8
1A
1000V
D9
1A
1000V
C1
A1
A4
C24
.022
2000V
C12
.022
2000V
B204
TRANSFORMER
PRIMARY
204
C28
.22
1000V
R78
1K
5W
202
C29
.22
1000V
325VDC
(NOMINAL)
B201
TRANSFORMER
PRIMARY
201
FILTER
CAPACITOR
207
C25
.022
2000V
C9
.022
2000V
203A
RECONNECT
202A
RECONNECT
R77
1K
5W
1K
5W
1K
5W
1K
5W
1K
5W
BLEEDER
RESISTORS
+15V
+
1
X2
TL431
-
6
8
REF
2.8K
562
C7
27
35V
1K
5W
1K
5W
1K
5W
BLEEDER
RESISTORS
1K
5W
DZ14
15V
1W
150K
150K
150K
150K
C21
27
35V
6.19K
+15V
D7
C5
150p
50V
+15V
D6
12
13
X1
R83
1.00M
14
D5
OVERVOLTAGE
PROTECTION
R119
221K
R118
221K
207A
NEGATIVE
INPUT RECTIFIER
31.6K
DZ16
12V
C14
1.0
35V
1W
221K
3
2
X1
R82
1.00M
1
D4
OVERVOLTAGE
PROTECTION
NOTE: 202,203,206,&207 BOLT ON WITH FILTER CAPS
ELECTRICAL DIAGRAMS
NOTES :
N.A. SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE
WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE
NUMBER.
UNDERVOLTAGE
D18
7
X1
6
PROTECTION
R92
22.1K
5
R85
1.00M
C16
1.0
35V
C17
18
15V
+15V
PEAK DETECTOR
D15
DZ15
12V
1W
Q2
1A
100V
R40
24.3K
9
C6
10
X1
MISCONNECTION
PROTECTION
R84
1.00M
8
D16
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
C13
50
25V
100K
44.2K
D3
+15V
Q3
1A
100V
OCI3
CNY17-3V
5
4 6
C18
150p
50V
2
1
1.00K
R97
CR2
2
CR1 2
1
1
D20
J10
1
(RELAY DRIVE)
FROM CONTROL BD.
J10
4
10K
10
9
X3
8
C15
150p
50V
1
2
1.00K
J10
5
6 4
5
OCI4
CNY17-3V TO CONTROL BD.
(VOLTAGE PROTECTION)
J10
2
V/F CONVERTER
+15V
R98
150K
R99
332K
5
6
X3
7
R100
16.5K
D21
R103
6.19K
R101
6.19K
R107
150K
R108
332K
D22
R111
C20
0.27
50V
1.0
1W Q4
1A
100V
R109
10.0K
+15V
R102
15.0K
13
X3
12
14
R110
15.0K
D23
Q5
1A
100V
1
X3
3
2
D24
R114
47.5K
300 Volts = 1kHz (calibrated) dF = 9.5136 dV
FILE NAME: G3518_1CA
GENERAL INFORMATION
ELECTRICAL SYMBOLS PER E1537
CAPACITORS = MFD ( .022/50V
RESISTORS = Ohms ( 1/4W
UNLESS OTHERWISE SPECIFIED)
UNLESS OTHERWISE SPECIFIED)
DIODES = 1A, 400V (UNLESS OTHERWISE SPECIFIED)
+15V
3-19-99A
G
3518
LAST NO. USED
R-
C-
D-
119
29
24
Q- 5
CR- 2
DZ- 16
X- 3
OCI- 4
T- 1 LABELS
SUPPLY VOLTAGE NET
POWER SUPPLY SOURCE POINT
COMMON CONNECTION
FRAME CONNECTION
EARTH GROUND CONNECTION
G-6
PRO-CUT 80
G-7
PC BOARD ASSEMBLY - POWER BOARD
ELECTRICAL DIAGRAMS
G-7
9.00
~.04
A1
A2
A4
A3
PRO-CUT 80
POWER
DZ1
DZ3
R13
DZ2
G3440-1
DZ8
DZ10
R62
DZ9
C10
R72
R79
R63
DZ11
DZ12
DZ13
R27
DZ15
R89
R87
R88
R47
D15
R23
R44
R40
R46
C21
R84
R41
R42
R53
R104
R105
R106
R99
R100
D22
R52
R43
R33
D6
R98
R49
R48
D7
R51
R107
R108
R109
C20
R119
R118
R93
R50
R82
D4
R92
C16
D18
D3
D23
R112
R113
R37
R39
R95
R36
DZ16
C14
R35
ITEM
C1,C4,C9,C12 )
C2,C3,C10,C11 )
C5,C15,C18 )
C6,C8,C19 )
C7,C21 )
C13 )
C14,C16 )
C17 )
C20 )
CR1,CR2 )
D1,D2,D8,D9 )
D3,D4,D5,D6,D7,D15,D16,D18 )
D20,D21,D22,D23,D24
DZ1,DZ3,DZ5,DZ6,DZ8,DZ10 )
DZ12,DZ13,DZ14
DZ2,DZ4,DZ9,DZ11 )
DZ7,DZ15,DZ16 )
J10 )
OCI1,OCI3,OCI4 )
Q1 )
Q2,Q3,Q4,Q5 )
R1,R2,R3,R4 )
R5,R6,R7,R8,R15,R16,R17 )
R18,R33,R37,R54,R55,R56
R57,R64,R65,R66,R67,R97
R9,R10,R11,R12,R13,R14,R19 )
R20,R21,R22,R58,R59,R60
R61,R62,R63,R68,R69,R70
R71
R23,R24,R25,R26,R34,R43 )
R51,R53,R98,R107
R27 )
R28,R36,R38,R44,R47,R87 )
R88,R96,R118,R119
R29,R30,R31,R32,R73,R74 )
R75,R76,R77,R78,R80,R81
R35 )
R39,R46,R49,R91,R109 )
R40 )
R41 )
R42 )
R45,R48,R94 )
R50,R52,R101,R103 )
R72,R79 )
R82,R83,R84,R85 )
R89,R90,R92 )
R93 )
R95 )
R99,R108 )
R100 )
R102,R110 )
R104 )
R105 )
R106 )
R111 )
R112,R113 )
R114 )
R115 )
R116,R117 )
T1 )
X1,X3 )
X2 )
9 )
20 )
10 )
1 )
10 )
12 )
CAPACITORS = MFD/VOLTS
RESISTORS = OHMS
1 )
1 )
1 )
2 )
1 )
1 )
2 )
1 )
2 )
1 )
3 )
1 )
1 )
2 )
1 )
2 )
1 )
1 )
5 )
1 )
1 )
1 )
3 )
4 )
2 )
4 )
4 )
3 )
1 )
3 )
1 )
4 )
4 )
19 )
REQ'D
4 )
4 )
3 )
3 )
2 )
1 )
2 )
1 )
1 )
2 )
4 )
13 )
PART NO.
S20500-7 )
S16668-6 )
S16668-9 )
S16668-5 )
S13490-93 )
S13490-83 )
S13490-42 )
S13490-39 )
S13490-130 )
S14293-18 )
T12705-44 )
T12199-1 )
T12702-29 )
T12702-40 )
T12702-19 )
S20351-6 )
S15000-22 )
T12704-75 )
T12704-73 )
S24376-2 )
S19400-1001 )
S19400-10R0 )
S19400-1503 )
S19400-1000 )
S19400-2213 )
T14648-19 )
S19400-3162 )
S19400-1002 )
S19400-2432 )
S19400-5620 )
S19400-2801 )
S19400-7681 )
S19400-6191 )
S19400-2001 )
S19400-1004 )
S19400-2212 )
S19400-1822 )
S19400-4751 )
S19400-3323 )
S19400-1652 )
S19400-1502 )
S19400-1372 )
S19400-1821 )
S19400-2941 )
T12300-79 )
S19400-2211 )
S19400-4752 )
T10812-41 )
S19400-3321 )
S13000-46 )
S15128-4 )
S15128-10 )
DESCRIPTION
.047/1600
4700pF/50
150pF/100
.022/50
27/35
50/25V
1.0/35
18/15
.27/50
DPST RELAY
DIODE 1000V/1A
1N4004
1N4744A
1N4735
1N4742A
HEADER
OPTO ISOLATOR
FET (SS)
IC PKG MOSFET (SS)
40/10W
1K 1/4W
10 1/4W
150K 1/4W
100 1/4W
221K 1/4W
1K 5W
31.6K 1/4W
10K 1/4W
24.3K 1/4W
562 1/4W
2.8K 1/4W
7.68K 1/4W
6.19K 1/4W
2.0K 1/4W
1M 1/4W
22.1K 1/4W
18.2K 1/4W
4.75K
332K 1/4W
16.5K 1/4W
15K 1/4W
13.7K 1/4W
1.82K 1/4W
2.94K 1/4W
1 WATT 1 OHM 1% RESISTOR
2.21K 1/4W
47.5K 1/4W
10K 1/2W TRIMMER
3.32K 1/4W
TRANSFORMER
IC,LM224,OP-AMP
IC,431,VOLTAGE REF.
R76 R75
0
0 12.00
~.04
G
3-19-99
3440-1B
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 provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.
PRO-CUT 80
G-8
SCHEMATIC - OUTPUT PC BOARD
(ELECTRODE)
CHOKE
ELECTRICAL DIAGRAMS
15W
R38
200
R4
R59
5.11K
R60
10W
R21
160
R25 R23
R61
3.74K
R1
15W 200
R55
1.00K
R36
332
R2
511
R22
3.32K
511
R34
3.74K
R3
511
R26
3.92K
R28
1.50K
R58
1.50K
R32
475
R24
1.21K
R27
221K
R7
332
R56
825
R9
221K
R54
2.00K
R12
3.92K
R6
1.50K
R8
1.50K
R31
475
R11
1.21K
R13
221K
511
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
R10
1.21K
G-8
PRO-CUT 80
G-9
PC BOARD ASSEMBLY - OUTPUT BOARD
ELECTRICAL DIAGRAMS
X4
B12
R4
D27 D28
A1
R3
B11
X2
J33
B21
R5
LED6
R55
R2
DZ9
C2
DZ10
DZ2
DZ1
Q6
R18
D30
R38
C11
R19
A2
B1
X20
B2
X40 C1
R1
D29
TP2 TP1 TP3
C37
C36
J31
D31
CR1
X1
R34
C19
R30
OCI1
D9
D24 D18
Q7
R61
DZ12
R59
C10
D22
D12
C9
C21
Q2 Q4
LED3
D25 D26
R58
R28
Q3 Q1
Q5
OCI2
D10
OCI3
D1
LED4
OCI4
LED2
R9
C8
C38
C18
G3439-1 OUTPUT
C16
Q8
DZ3
D23
LED1
R22
D16
D17
D15
D14
J30
J34 J32
ITEM
C1,C3,C11,C15,C34,C35 )
C2 )
C4,C26,C27,C30,C36,C37 )
C5,C6,C7,C25 )
C8,C12,C17 )
C9,C10,C21 )
C13 )
C14 )
C16 )
C18 )
C20,C22,C23,C24,C29,C38 )
C28 )
C31,C32 )
C33 )
CR1 )
D10,D11,D13,D14,D15,D16
D17,D19,D20,D21,D23,D25
D26,D31
D12,D22 )
D18,D24 )
D27,D28,D29,D30 )
DZ1,DZ2,DZ9,DZ10 )
DZ3 )
DZ7,DZ8,DZ11,DZ12 )
J30 )
J31 )
J32 )
J33 )
J34 )
L1 )
LED1,LED2 )
LED3,LED4,LED5,LED6 )
OCI1 )
OCI2,OCI3,OCI4 )
Q1,Q3,Q7,Q8 )
Q2,Q4 )
Q5 )
Q6 )
R1,R38 )
R2 )
R3,R4 )
R5 )
R6,R8,R28,R58 )
R9,R13,R27 )
R10,R11,R24,R29,R62 )
R12,R26 )
R14,R15,R16,R17,R33 )
R18,R19 )
R20,R54 )
R21 )
R22 )
R23,R25 )
R30 )
R31,R32 )
R34,R61 )
R35 )
R50,R51,R52,R53,R65,R66 )
R55,R60 )
R56 )
R57 )
R59 )
R63 )
R64 )
TP1,TP2,TP3 )
TP4 )
TP5 )
X1 )
REQ'D PART NO
3 )
1 )
1 )
1 )
1 )
6 )
1 )
6 )
4 )
3 )
6 )
1 )
2 )
1 )
1 )
S20500-5 )
S13490-42 )
T11577-58 )
S20500-1 )
S16668-7 )
T11577-52 )
S13490-72
S13490-71
S13490-93
S13490-121
S16668-5 )
S16668-11 )
T11577-46 )
T11577-57 )
S13929-10 )
1 )
1 )
3 )
1 )
1 )
1 )
6 )
2 )
1 )
1 )
1 )
2 )
1 )
1 )
2 )
1 )
2 )
2 )
1 )
3 )
5 )
2 )
5 )
2 )
4 )
1 )
1 )
1 )
1 )
1 )
1 )
2 )
4 )
2 )
2 )
4 )
4 )
1 )
1 )
3 )
4 )
2 )
1 )
1 )
2 )
1 )
2 )
1 )
4 )
T12705-34 )
T12705-50 )
T12705-46 )
T12702-29 )
T12702-23 )
T12702-19 )
S20351-6 )
S20351-10 )
S20351-14 )
S20351-4 )
S20351-8 )
T12218-2 )
T13657-2 )
T13657-3 )
S15000-26 )
S15000-10 )
T12704-73 )
T12704-80 )
T12704-68 )
T12704-86 )
T12300-47 )
S19400-5110 )
T12300-66 )
T14648-2 )
S19400-1501 )
S19400-2213 )
S19400-1211 )
S19400-3921 )
S18380-3 )
S23995-1 )
S19400-2001 )
T14649-11 )
S19400-3321 )
T14650-4 )
S19400-4751 )
S19400-4750 )
S19400-3741 )
T14649-4 )
T14650-1 )
S19400-1001 )
S19400-8250 )
S19400-8251 )
S19400-5111 )
T14650-2 )
S18380-9 )
T13640-20 )
T13640-9 )
T13640-15 )
S15018-19 )
CAPACITORS = MFD/VOLTS
RESISTORS = OHMS
IDENTIFICATION
.0015/2000V
1.0/35
.0047/3000V
.1/1000
820pF/50
.0047 or .005/1400
.022/50
.1/50
.05/600V
0.1/400
RELAY,DPDT,24VDC
1N4936
DIODE
1000V/3AMP DIODE
1N4744A
1N5352B
1N4742A
HEADER
RT. ANGLE HEADER
HEADER
HEADER
HEADER
5.6mH
RED LED
GREEN LED
OPTOCOUPLER,LOGIC-OUT
OPTO ISOLATOR
IC PKG MOSFET (SS)
HEXFET TRANS. (SS)
2N4401
TRANSISTOR,IGBT,1200V,45A
15 W 200 OHM RESISTOR
511 1/4W
15W / 56 OHM PWR RESISTOR
25 5W
1.5K 1/4W
221K 1/4W
1.21K 1/4W
3.92K 1/4W
THERMISTOR,PTC,0.08-0.19 OHMS,1.85A
SHUNT RESISTOR,.001 OHM,4W
2.0K 1/4W
160/10W
3.32K 1/4W
15W.,2500 OHM RESISTOR
4.75K
475 1/4W
3.74K 1/4W
100 10W
1500 OHMS, 15 W. RESISTOR
1K 1/4W
825 1/4W
8.25K 1/4W
5.11K 1/4W
80 15W
THERMISTOR,PTC,10 OHMS,400MA
480V/180J MOV
20J
15J
IC,DRIVER,FET,6A
G-9
3-19-99
G
3439-1
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 provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.
PRO-CUT 80
G-10
SCHEMATIC - DISPLAY PC BOARD
ELECTRICAL DIAGRAMS
G-10
"READY"
SIGNAL
14
J40
3.32K
R1
C1
2700p
50V
Q1
2N4401
"AIR LOW"
SIGNAL
13
J40
3.32K
R5
C2
2700p
50V
Q2
2N4401
"THERMAL"
SIGNAL
9
J40
3.32K
R9
C3
2700p
50V
Q3
2N4401
"SAFETY"
SIGNAL
8
J40
3.32K
R13
C4
2700p
50V
Q4
2N4401
15
J40
+15V
C5
4.7
35V
10
J40
COM
COM
COM
COM
COM
100
R3
100
R7
100
R11
R15
75.0
100
R4
100
R8
100
R12
R16
75.0
+15V
+15V
1
1 7
2 8
4
3
LED8
5
6
2
3
4
5
6
7
LED9
8
8
LED6
7
6
5
4
3
2
2
1 7
8
4
3
LED7
5
6
1
1
1 7
2 8
4
3
LED4
5
6 4
5
2
3
6
7
8
LED5
7
6
5
4
3
2
8
LED3
1
1 7
+15V
4
2 8 3
4 6 2
LED2 LED1
3 5 1
243
R20
NOTES :
N.A. SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE
WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE
NUMBER.
7
J40
J40
5
+15V
DZ1
10V
1W
COM
J40
2
1
J40
+15V
11
J40
12
J40
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
+15V
J40
3
J40
4
AIR SET
RESET
10K
CONTROL
POT
J40
FILENAME: M18920_1AA
6
J40
GENERAL INFORMATION
ELECTRICAL SYMBOLS PER E1537
CAPACITORS = MFD ( .022/50V
RESISTORS = Ohms ( 1/4W
UNLESS OTHERWISE SPECIFIED)
UNLESS OTHERWISE SPECIFIED)
DIODES = 1A, 400V (UNLESS OTHERWISE SPECIFIED)
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
LAST NO. USED
R-
C-
20
5
DZ- 1
LED9
LABELS
SUPPLY VOLTAGE NET
POWER SUPPLY SOURCE POINT
COMMON CONNECTION
FRAME CONNECTION
EARTH GROUND CONNECTION
10-31-97D
M 18920
PRO-CUT 80
G-11
PC BOARD ASSEMBLY - DISPLAY BOARD
ELECTRICAL DIAGRAMS
G-11
ITEM
C1,C2,C3,C4
C5
DZ1
LED1
LED2,LED7
LED3,LED6
LED4
LED5
LED8
LED9
Q1,Q2,Q3,Q4
R1,R5,R9,R13
R2,R6,R10,R14
R3,R4,R7,R8,R11,R12
R15,R16
R17
R18,R19
R20
1
1
4
1
1
1
2
2
1
2
1
6
2
4
4
QTY.
4
1
1
PART No.
S16668-4
S13490-25
T12702-27
M18875-1
M18875-5
M18875-2
M18875-6
M18875-3
M18875-7
M18875-4
T12704-68
S19400-3321
S19400-6811
S19400-1000
S19400-75R0
S19400-8250
S19400-2671
S19400-2430
IDENTIFICATION
2700pF/50
4.7/35
1N4740
LIGHT BAR,LED,YELLOW
LIGHT BAR,LED,RED
LIGHT BAR,LED,RED
LIGHT BAR,LED,YELLOW
LIGHT BAR,LED,YELLOW
LIGHT BAR,LED,GREEN
LIGHT BAR,LED,GREEN
2N4401
3.32K 1/4W
6.81K 1/4W
100 1/4W
75 1/4W
825 1/4W
2.67K 1/4W
243 1/4W
1.10
4.00
1.65~.04
1.40
1.00
Q1
LED9
LED8
R8
Q2
LED6
LED7
Q4
R14
Q3
C4
LED5
LED4
DZ1
LED3
LED2
R20
LED1
C5
J40
L10721-1
.20
0
0
4.30
4.50~.04
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 provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.
PRO-CUT 80
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 column troubleshooting chart, please share this information with us. Please include the machine’s code number and how the problem was resolved.
Thank You,
Technical Services Group
Lincoln Electric Co.
22801 ST. Clair Ave.
Cleveland, Ohio 44117-1199
FAX 216-481-2309
SVM Number ___________________________
Page Number if necessary__________________
Your Company__________________________
Your Name_____________________________
Please give detailed description below:
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
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SD287 01/99
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