Download Python Service Manual - Red-D
Transcript
SVM146-A September, 1999 ™ PRO-CUT 80 For use with machine code numbers 10573, 10574, 10577, 10578 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation . . . and thoughtful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED 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 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 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.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot. 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.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. ____________________________________________________ ELECTRIC AND MAGNETIC FIELDS may be dangerous 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. PRO-CUT 80 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. ii ii SAFETY ELECTRIC SHOCK can kill. ARC RAYS can burn. 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. 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. 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. 4.b. Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays. 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. 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. 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. 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. PRO-CUT 80 iii iii SAFETY WELDING SPARKS can cause fire or explosion. CYLINDER may explode if damaged. 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. 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. 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. • 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. PRO-CUT 80 iv SAFETY 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. iv Protegez-vous contre la secousse électrique: a. b. 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. 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. 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. PRÉCAUTIONS DE SÛRETÉ POUR LES MACHINES À SOUDER À TRANSFORMATEUR 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 v MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page Safety.................................................................................................................................................i-iv Installation .............................................................................................................................Section A Technical Specifications ..........................................................................................................A-2/3 Safety Precautions......................................................................................................................A-4 Select Suitable Location .............................................................................................................A-4 Stacking ......................................................................................................................................A-4 Lifting and Moving ......................................................................................................................A-4 Tilting...........................................................................................................................................A-4 High Frequency Interference Protection.....................................................................................A-4 Input Electrical Connections.......................................................................................................A-5 Input Power Cord Connector Installation ...................................................................................A-5 Frame Grounding ........................................................................................................................A-5 Gas Input Connections ...............................................................................................................A-7 Output Connections....................................................................................................................A-8 Operation...............................................................................................................................Section B Safety Precautions......................................................................................................................B-2 General Description ....................................................................................................................B-3 Recommended Processes and Equipment................................................................................B-3 Operational Features and Controls ............................................................................................B-3 Design Features and Advantages ..............................................................................................B-3 Cutting Capability .......................................................................................................................B-4 Consumable Life.........................................................................................................................B-4 Limitations ..................................................................................................................................B-4 Controls and Settings.................................................................................................................B-5 Pilot Arc Discussion....................................................................................................................B-5 Cutting Operation .......................................................................................................................B-5 User Responsibility.....................................................................................................................B-7 Preheat Temperature for Plasma Cutting ...................................................................................B-7 Procedure Recommendations ....................................................................................................B-7 Accessories...........................................................................................................................Section C Maintenance .........................................................................................................................Section D Theory of Operation .............................................................................................................Section E Troubleshooting and Repair.................................................................................................Section F Safety Precautions ......................................................................................................................F-2 How to Use Troubleshooting Guide............................................................................................F-2 Troubleshooting Guide ................................................................................................................F-4 Test Procedures ........................................................................................................................F-10 Replacement Procedures .........................................................................................................F-40 Electrical Diagrams ..............................................................................................................Section G Parts Manual ....................................................................................................................P-340 Series PRO-CUT 80 Section A-1 TABLE OF CONTENTS - INSTALLATION SECTION - Section A-1 Installation Technical Specifications .............................................................................................................A-2 Safety Precautions......................................................................................................................A-4 Select Suitable Location.............................................................................................................A-4 Stacking ......................................................................................................................................A-4 Lifting and Moving ......................................................................................................................A-4 Tilting ..........................................................................................................................................A-4 High Frequency Interference Protection.....................................................................................A-4 Input Electrical Connections.......................................................................................................A-5 Ground Connection ..............................................................................................................A-5 Input Power Cord Connector Installation ...................................................................................A-5 Input Wire and Fuse Size .....................................................................................................A-5 Reconnect Procedure...........................................................................................................A-6 Gas Input Connections...............................................................................................................A-7 Output Connections ...................................................................................................................A-8 Torch Connection .................................................................................................................A-8 PRO-CUT 80 A-2 A-2 INSTALLATION TECHNICAL SPECIFICATIONS - PRO-CUT 80 INPUT RATINGS Single Phase Input Voltage and Hertz Input Currents Rated Output Amps 208/1/60 230/1/60 460/1/60 87 81 48 80 80 80 Three Phase Input Voltage and Hertz Input Currents Rated Output Amps 208/3/60 230/3/60 460/3/60 48 44 25 80 80 80 IDLE CURRENT AND WATTS IDLE CURRENT AND WATTS 230/1/60 0.61 Amps 140 Watts RATED OUTPUT Duty Cycle Rated Output Amps 60% 100% 80 60 OUTPUT Current Range Open Circuit Voltage Pilot Current 35 - 85 Amps 335VDC Maximum 20 Amps @ 100% Duty Cycle PRO-CUT 80 A-3 A-3 INSTALLATION TECHNICAL SPECIFICATIONS (Cont’d) - PRO-CUT 80 GAS REQUIREMENTS Required Gas Flow Rate Required Gas Inlet Pressure 70 PSI @ 480 SCHF (4.8 Bar. @ 13550 LHR) 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 100 Amps 60 Amps #4 (21.1mm2) #8 (8.4mm2) #4 (21.1mm2) #8 (8.4mm2) 230VAC Three Phase 460VAC Three Phase 60 Amps 40 Amps #8 (8.4mm2) #10 (5.3mm2) #8 (8.4mm2) #10 (5.3mm2) PHYSICAL DIMENSIONS Height Width Depth Weight with Torch Cable 16.5 Inches 419 mm 13.75 Inches 349 mm 29.5 Inches 749 mm 98 lbs. (44.5 kg.) (25 ft. cable) 113 lbs. (51.4 kg.) (50 ft. cable) PRO-CUT 80 A-4 A-4 INSTALLATION Read this entire installation section before you start installation. LIFTING AND MOVING WARNING SAFETY PRECAUTIONS FALLING EQUIPMENT can cause injury. WARNING ¥ 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. 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. 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. ¥ Either the front or rear handles or both may be used to lift or move the machine. 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 INSTALLATION INPUT CONNECTIONS A-5 GROUND CONNECTION 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. 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. ¥ Do not touch electrically hot parts. Before installing the machine, check that input supply voltage, phase, and frequency are the same as the machineÕ s voltage, phase, and frequency as specified on the machineÕ s rating plate. See Figure A.1. FIGURE A.1 Ð RATING PLATE LOCATION 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. 1 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. 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 ÒnuisanceÓ shut-of fs from inrush currents, even if you are not cutting at high currents. 2 3 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 A-6 INSTALLATION RECONNECT PROCEDURE FIGURE A.2 Ð RECONNECTION DIAGRAM 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. RECONNECT PROCEDURE WARNING ¥ Disconnect input power before inspecting or servicing machine. ¥ Do not operate with wraparound removed. CAUTION Failure to follow these instructions can cause immediate failure of components in the welder. 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 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. 380 - 415V 220 - 230V 'A' 200 - 208V 3. POSITION SWITCH TO DESIRED INPUT VOLTAGE RANGE. For 460: Position the large switch to 380-460. See Figure A-2. VOLTAGE = 380 - 460V 3. Move the ÒAÓ lead to the appr opriate terminal. VOLTAGE = 200 - 230V PRO-CUT 80 A-7 A-7 INSTALLATION GAS INPUT CONNECTIONS FIGURE A.3 - COMPRESSED GAS CONNECTION Supply the PRO-CUT 80 with clean compressed air or nitrogen. • Supply pressure must be between 80 psi and 150 psi. 1 • 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. 2 • Connect the gas supply to the PRO-CUT 80’s pneumatic nipple at the air filter. See Figure A.3. 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. 4 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. 1. 2. 3. 4. CASE BACK PNEUMATIC NIPPLE AIR FILTER FLEX TUBE (TO REGULATOR INSIDE MACHINE) • Never allow the cutting torch to touch the cylinder. • Keep cylinder away from live electrical parts. • Maximum inlet pressure 150 psi. NOTE: When using nitrogen gas from a cylinder, the cylinder must have a pressure regulator. • Maximum psi from nitrogen gas cylinder to PROCUT 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 FIGURE A.4 - TORCH CONNECTION AT CASE FRONT TORCH CONNECTION Status Indicators 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 OperatorÕ s Manual (IM595). Reset Button XXXX XXXX XXXX Gas Purge Button Gas Regulator Gauge XXXX Gas Regulator Knob Output Control Knob P R O-C UT 80 Consumable Storage (behind door) Torch Connector PRO-CUT 80 Input Power Switch Work Cable Interface Connector Section B-1 Section B-1 TABLE OF CONTENTS - OPERATION SECTION Operation...............................................................................................................................Section B Safety Instructions ......................................................................................................................B-2 General Description ....................................................................................................................B-3 Recommended Process and Equipment....................................................................................B-3 Operational Features and Controls ............................................................................................B-3 Design Features and Advantages...............................................................................................B-3 Cutting Capability .......................................................................................................................B-4 Consumable Life.........................................................................................................................B-4 Limitations...................................................................................................................................B-4 Controls and Settings .................................................................................................................B-5 Pilot Arc Considerations .............................................................................................................B-5 Cutting Operation .......................................................................................................................B-5 Safety Status Indicator .............................................................................................................. B-6 User Responsibility .....................................................................................................................B-7 Preheat Temperature for Plasma Cutting ...................................................................................B-7 Procedure Recommendations ....................................................................................................B-7 General .................................................................................................................................B-7 Thin Gauge Sheet Metal ......................................................................................................B-7 Thick Sections of Metal........................................................................................................B-8 Suggestions for Extra Utility From the Pro-Cut System ......................................................B-8 Machine Interface........................................................................................................................B-9 Arc Start.......................................................................................................................................B-9 Arc Initiated.................................................................................................................................B-9 Arc Voltage..................................................................................................................................B-9 PRO-CUT 80 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 OPERATION GENERAL DESCRIPTION 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 25Õ or 50Õ cable, machine and robotic torch both with 25Õ and 50Õ 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. B-3 DESIGN FEATURES AND ADVANTAGES 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. ¥ ÓParts-in-PlaceÓ mechanism to detect pr oper 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. OPERATIONAL FEATURES AND CONTROLS ¥ Display indicators for machine status. 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 discussion. ¥ Swirl texture inside Vortechª nozzle for better start ing reliability and higher quality cuts. ¥ Unique electrode and Vortechª nozzle design for optimum cooling and long life. ¥ Unique drag cup design for durability and elimination of double arcing. PRO-CUT 80 B-4 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 Ð LINCOLNÕS PRO-CUT 80 MILD STEEL CUT CAP ACITY CHART Lincoln's PRO-CUT 80 Mild Steel Cut Capacity Chart Recommended Torch Travel Speed (IPM) 80% of Maximum Speed 100 80 60 40 20 25 A 0 0.000 0.125 55 A 35 A 0.250 0.375 0.500 Material Thickness 0.625 0.750 80 A 1.00 CONSUMABLE LIFE LIMITATIONS 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. Do not exceed output current and duty cycle rating of machine. Do not use the PRO-CUT 80 for pipe thawing. 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. PRO-CUT 80 B-5 OPERATION CONTROLS AND SETTINGS FIGURE B.2 - CASE FRONT CONTROLS Status Indicators Reset Button XXXX XXXX XXXX Gas Purge Button Gas Regulator Gauge XXXX Gas Regulator Knob Output Control 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. PRO-CUT 80 Consumable Storage (behind door) Torch Connector B-5 CUTTING OPERATION Input Power Switch Work Cable Interface Connector 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. 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 formation 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. 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 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 300 ANGLE TO PIERCE 5ϒ - 15ϒ Leading Angle Direction of Travel 10ϒ - 20ϒ Arc Lag ¥ 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 3/16Ó (4.7mm) above the workpiece. ANGLE OF APPROACH ROTATE TO 0 90 ANGLE TO CUT 300 900 VERTICAL ANGLE VERTICAL FOR CUTTING TORCH HELD AT 450 ANGLE THROUGHOUT GOUGE CUT ¥ 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. ¥ 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. ¥ Use a 5¡ - 15¡ leading angle in the direction of the cut. ¥ Use the drag cup to maintain constant standoff for better cut quality and to protect the nozzle from spatter. ANGLE MAINTAINED THROUGHOUT GOUGE SAFETY STATUS INDICATOR ¥ If the "SAFETY" status indicators light at any time, check the following: - Check the assembly of the torch consumables. If they are not properly in place, the machine will not start. Make sure that the shield cup is hand tight. Do not use pliers or overtighten. ¥ Use the drag cup with a metal template to prevent nozzle double arcing. PRO-CUT 80 B-7 B-7 OPERATION PREHEAT TEMPERATURE FOR PLASMA CUTTING WARNING ELECTRIC SHOCK can kill. ¥ Turn off machine at the disconnect switch on the front of the machine before tightening, cleaning or replacing consumables. - Check the conditions of the inside of the nozzle. If debris has collected, rub the electrode on the inside bottom of the nozzle to remove any oxide layer that may have built up. Refer to ÒSuggestions for Extra Utility from the Pro-Cut System.Ó - 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.) 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. 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 ¥ If the machine does not reset or continues to trip, consult the Troubleshooting Section. Torch Standoff Machine Output Setting ¥ Use the proper cutting or gouging procedures referred to in ÒProcedure RecommendationsÓ below. 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 Setting Min. thru Mid. Range Output set below 45 Amps. ¥ 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 OPERATION THICK SECTIONS OF METAL Torch Standoff Machine Output Setting 45 1/8" thru 3/16" Standoff Output Setting Mid. thru Max. Range Output set above 45 Amps. B-8 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: ¥ 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. a. Never drag the nozzle on the work surface if the output control knob is above 45 Amps. ¥ 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. c. Use the lowest output setting possible to make a good quality cut at the desired cut speed. ¥ 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. b. Make sure the air supply to the Pro-Cut is clean and free of oil. Use several extra in-line filters if necessary. 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). Arc Start K=2A Arc Initiated J=347 M=4A I=348 L H C N G=343 D=344 F E Arc Voltage 14-PIN BOX RECEPTACLE, FRONT VIEW 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 PRO-CUT 80 B-10 Section C-1 Section C-1 TABLE OF CONTENTS - ACCESSORIES Accessories...........................................................................................................................Section C Options/Accessories...................................................................................................................C-2 PRO-CUT 80 C-2 ACCESSORIES GENERAL OPTIONS / ACCESSORIES C-2 ALWAYS USE GENUINE LINCOLN ELECTRIC ELECTRODES AND VORTECHª NOZZLES 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. ¥ Only Genuine Lincoln Electric consumables yield the best cutting performance for the PRO-CUT 80. ¥ The patent pending VORTECHª nozzle pr ovides an extra ÒkickÓ of swirl as the ar c exits the nozzle, which improves cutting performance. No other nozzle has this capability or can match its performance. S22147-043 - Vortechª nozzle with an .043Ó (1.2 mm) Orifice (For 35 - 60 Amps) S22147-053 - Vortechª nozzle with an .053Ó (1.3 mm) Orifice (For 60 - 85 Amps) S22147-082 - VortechTM nozzle with an .082Ó (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 25Õ and 50Õ lengths in either hand held or mechanized versions. PRO-CUT 80 Section D-1 Section D-1 TABLE OF CONTENTS -MAINTENANCEMaintenance .........................................................................................................................Section D Safety Precautions......................................................................................................................D-2 Input Filter Capacitor Discharge Procedure ...............................................................................D-2 Routine Maintenance..................................................................................................................D-3 Periodic Maintenance .................................................................................................................D-3 Major Component Locations .....................................................................................................D-4 PRO-CUT 80 D-2 D-2 MAINTENANCE 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. 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. 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. 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. 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. 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. FIGURE D.1 Ñ LOCA TION OF INPUT FILTER CAPACITOR TERMINALS POWER BOARD CAPACITOR TERMINALS POWER RESISTOR RIGHT SIDE OF MACHINE INSULATED GLOVES PRO-CUT 80 INSULATED PLIERS 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. WARNING ELECTRIC SHOCK can kill. 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 FIGURE D.2 - Power, Output and Control printed circuit boards and heat sinks • Turn off machine at the disconnect switch on the front of the machine before tightening, cleaning or replacing consumables. 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. 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. 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. 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. 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. 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. 2. Filter Capacitor Conditioning (PRO-CUT 80, 400460 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: a. Machine is connected 460-575 VAC input. for 400-460 or 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 D-4 Maintenance FIGURE D.2 Ð 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 4 3 5 1 2 PRO-CUT 80 Section E-1 Section E-1 TABLE OF CONTENTS -THEORY OF OPERATION SECTIONTheory of Operation .............................................................................................................Section E General Description ....................................................................................................................E-2 Input Line Voltage, Contactor and Main Transformer.................................................................E-2 Precharge and Protection ...........................................................................................................E-3 Main Transformer ........................................................................................................................E-4 Output Board and Torch .............................................................................................................E-5 Control and Display Boards........................................................................................................E-6 Protection Circuits ......................................................................................................................E-7 Overload Protection..............................................................................................................E-7 Thermal Protection ...............................................................................................................E-7 Insulated Gate Bipolar Transistor (IGBT) Operation ...................................................................E-8 Pulse Width Modulation (PWM) ..................................................................................................E-9 Minimum Output...................................................................................................................E-9 Maximum Output..................................................................................................................E-9 FIGURE E.1 – PRO-CUT 80 BLOCK LOGIC DIAGRAM WORK NOZZLE ELECTRODE POWER BOARD MAIN TRANSFORMER CR 1&2 RELAY INPUT LINE SWITCH OUTPUT TORCH CONNECTOR BOARD E L E C T R O D E IGBT INPUT RECTIFIER CAPACITOR CHOKE R E C O N N E C T PILOT TRANSISTOR IGBT D IGBT CURRENT TRANSFORMER S W I T C H S O L E N O I TRIGGER & SAFETY CAPACITOR AIR SOLENOID IGBT AIR PRESSURE SWITCH "A" L E P R O T E C T I O N TRIGGER & SAFETY CR 1 & 2 RELAY DRIVE SIGNAL REMOTE INTERFACE RECEPTACLE IGBT GATE SIGNALS ELECTRODE & TRANSFER CURRENT FEEDBACK SIGNAL A PILOT ENABLE CONTROL BOARD ELECTRODE SOLENOID ENABLE D AIR SOLENOID ENABLE 18/36VAC THERMOSTATS R E A D Y A I R L O W T H E R M A L S A F E T Y OUTPUT CONTROL DISPLAY BOARD 12VAC 24VAC 115VAC AUXILIARY TRANSFORMER FAN MOTOR PRO-CUT 80 E-2 E-2 THEORY OF OPERATION FIGURE E.2 Ð INPUT LINE VOLTAGE WORK NOZZLE ELECTRODE POWER BOARD MAIN TRANSFORMER CR 1&2 RELAY INPUT LINE SWITCH OUTPUT TORCH CONNECTOR BOARD E L E C T R O D E IGBT INPUT RECTIFIER CAPACITOR CHOKE R E C O N N E C T PILOT TRANSISTOR IGBT D IGBT CURRENT TRANSFORMER S W I T C H S O L E N O I TRIGGER & SAFETY CAPACITOR AIR SOLENOID IGBT "A" AIR PRESSURE SWITCH L E P R O T E C T I O N TRIGGER & SAFETY CR 1 & 2 RELAY DRIVE SIGNAL REMOTE INTERFACE RECEPTACLE IGBT GATE SIGNALS ELECTRODE & TRANSFER CURRENT FEEDBACK SIGNAL A PILOT ENABLE CONTROL BOARD D ELECTRODE SOLENOID ENABLE AIR SOLENOID ENABLE 18/36VAC THERMOSTATS R E A D Y A I R L O W T H E R M A L S A F E T Y OUTPUT CONTROL DISPLAY BOARD 12VAC 24VAC 115VAC AUXILIARY TRANSFORMER 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 PROCUT 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 WORK NOZZLE ELECTRODE POWER BOARD MAIN TRANSFORMER CR 1&2 RELAY INPUT LINE SWITCH OUTPUT TORCH CONNECTOR BOARD E L E C T R O D E IGBT INPUT RECTIFIER CAPACITOR CHOKE R E C O N N E C T PILOT TRANSISTOR IGBT D IGBT CURRENT TRANSFORMER S W I T C H S O L E N O I TRIGGER & SAFETY CAPACITOR AIR SOLENOID IGBT "A" AIR PRESSURE SWITCH L E P R O T E C T I O N TRIGGER & SAFETY CR 1 & 2 RELAY DRIVE SIGNAL REMOTE INTERFACE RECEPTACLE IGBT GATE SIGNALS ELECTRODE & TRANSFER CURRENT FEEDBACK SIGNAL A PILOT ENABLE CONTROL BOARD D ELECTRODE SOLENOID ENABLE AIR SOLENOID ENABLE 18/36VAC THERMOSTATS R E A D Y A I R L O W T H E R M A L S A F E T Y OUTPUT CONTROL DISPLAY BOARD 12VAC 24VAC 115VAC AUXILIARY TRANSFORMER 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 Ð MAIN TRANSFORMER WORK NOZZLE ELECTRODE POWER BOARD MAIN TRANSFORMER CR 1&2 RELAY INPUT LINE SWITCH OUTPUT TORCH CONNECTOR BOARD E L E C T R O D E IGBT INPUT RECTIFIER CAPACITOR CHOKE R E C O N N E C T PILOT TRANSISTOR IGBT D IGBT CURRENT TRANSFORMER S W I T C H S O L E N O I TRIGGER & SAFETY CAPACITOR AIR SOLENOID IGBT "A" AIR PRESSURE SWITCH L E P R O T E C T I O N TRIGGER & SAFETY CR 1 & 2 RELAY DRIVE SIGNAL REMOTE INTERFACE RECEPTACLE IGBT GATE SIGNALS ELECTRODE & TRANSFER CURRENT FEEDBACK SIGNAL A PILOT ENABLE CONTROL BOARD D ELECTRODE SOLENOID ENABLE AIR SOLENOID ENABLE 18/36VAC THERMOSTATS R E A D Y A I R L O W T H E R M A L S A F E T Y OUTPUT CONTROL DISPLAY BOARD 12VAC 24VAC 115VAC AUXILIARY TRANSFORMER 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 E-5 THEORY OF OPERATION FIGURE E.5 Ð PLASMA OUTPUT BOARD AND TORCH WORK NOZZLE ELECTRODE POWER BOARD MAIN TRANSFORMER CR 1&2 RELAY INPUT LINE SWITCH OUTPUT TORCH CONNECTOR BOARD E L E C T R O D E IGBT INPUT RECTIFIER CAPACITOR CHOKE R E C O N N E C T PILOT TRANSISTOR IGBT D IGBT CURRENT TRANSFORMER S W I T C H S O L E N O I TRIGGER & SAFETY CAPACITOR AIR SOLENOID IGBT "A" AIR PRESSURE SWITCH L E P R O T E C T I O N TRIGGER & SAFETY CR 1 & 2 RELAY DRIVE SIGNAL REMOTE INTERFACE RECEPTACLE IGBT GATE SIGNALS ELECTRODE & TRANSFER CURRENT FEEDBACK SIGNAL A PILOT ENABLE CONTROL BOARD D ELECTRODE SOLENOID ENABLE AIR SOLENOID ENABLE 18/36VAC R E A D Y THERMOSTATS A I R L O W T H E R M A L S A F E T Y OUTPUT CONTROL DISPLAY BOARD 12VAC 24VAC 115VAC AUXILIARY TRANSFORMER 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-CutÕ 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 Ð CONTROL AND DISPLAY BOARDS WORK NOZZLE ELECTRODE POWER BOARD MAIN TRANSFORMER CR 1&2 RELAY INPUT LINE SWITCH OUTPUT TORCH CONNECTOR BOARD E L E C T R O D E IGBT INPUT RECTIFIER CAPACITOR CHOKE R E C O N N E C T PILOT TRANSISTOR IGBT D IGBT CURRENT TRANSFORMER S W I T C H S O L E N O I TRIGGER & SAFETY CAPACITOR AIR SOLENOID IGBT "A" AIR PRESSURE SWITCH L E P R O T E C T I O N TRIGGER & SAFETY CR 1 & 2 RELAY DRIVE SIGNAL REMOTE INTERFACE RECEPTACLE IGBT GATE SIGNALS ELECTRODE & TRANSFER CURRENT FEEDBACK SIGNAL A PILOT ENABLE CONTROL BOARD D ELECTRODE SOLENOID ENABLE AIR SOLENOID ENABLE 18/36VAC THERMOSTATS R E A D Y A I R L O W T H E R M A L S A F E T Y OUTPUT CONTROL DISPLAY BOARD 12VAC 24VAC 115VAC AUXILIARY TRANSFORMER 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 THEORY OF OPERATION E-7 PROTECTION CIRCUITS THERMAL PROTECTION 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. 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. 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. 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. FIGURE E.7 Ð CONTROL AND DISPLAY BOARDS POSITIVE VOLTAGE APPLIED SOURCE n+ GATE SOURCE n+ n+ GATE n+ p BODY REGION p BODY REGION n- DRAIN DRIFT REGION n- DRAIN DRIFT REGION n+ BUFFER LAYER n+ BUFFER LAYER p+ INJECTING LAYER p+ INJECTING LAYER DRAIN DRAIN B. ACTIVE A. PASSIVE PRO-CUT 80 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. 1 E-9 The positive portion of the signal represents one IGBT group1 conducting for 1 microsecond. The negative portion is the other IGBT group1. 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. An IGBT group consists of two IGBT modules feeding one transformer primary winding. FIGURE E.8 Ð TYPICAL IGBT OUTPUTS sec 48 50 sec sec sec MINIMUM OUTPUT 22 sec 3 sec 50 sec MAXIMUM OUTPUT PRO-CUT 80 22 sec E-10 NOTES PRO-CUT 80 E-10 Section F-1 Section F-1 TABLE OF CONTENTS TROUBLESHOOTING & REPAIR SECTION Troubleshooting & Repair Section .................................................................................Section F How to Use Troubleshooting Guide ......................................................................................F-2 PC Board Troubleshooting Procedures and Replacement ...................................................F-3 Troubleshooting Guide...........................................................................................................F-4 Test Procedures Input Filter Capacitor Discharge Procedure..................................................................F-10 Input Rectifier Test ........................................................................................................F-12 Primary Power Board Resistance Test and Capacitor Voltage Test .............................F-15 Output Power Board Resistance Test...........................................................................F-20 Torch Continuity and Solenoid Test ..............................................................................F-23 Air/Gas Solenoid Test....................................................................................................F-25 T2 Auxiliary Transformer Test ........................................................................................F-27 Trigger Circuit Test ........................................................................................................F-30 Low Voltage Circuit Test................................................................................................F-35 Replacement Procedures Control Board Removal and Replacement ...................................................................F-40 Display Board Removal and Replacement ...................................................................F-43 Output Power Board Removal and Replacement.........................................................F-46 Primary Power Board and Filter Capacitor Removal and Replacement ......................F-50 Input Rectifier Bridge Removal and Replacement........................................................F-54 Retest after Repair ........................................................................................................F-57 PRO-CUT 80 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 (SYMPTOMS). 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 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. 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. 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. 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-2 F-3 TROUBLESHOOTING & REPAIR F-3 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: • 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. 1. Determine to the best of your technical ability that the PC board is the most likely component causing the failure symptom. NOTE: Allow the machine to heat up so that all electrical components can reach their operating temperature. 2. Check for loose connections at the PC board to assure that the PC board is properly connected. 5. Remove the replacement PC board and substitute it with the original PC board to recreate the original problem. 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: 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. 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. 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. • Tools which come in contact with the PC Board must be either conductive, anti-static or static-dissipative. PRO-CUT 80 F-4 F-4 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS 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, Machine is dead – no output – no fan – no status indicator lights. 1. Make sure that the input power switch is in the “ON” position. 1. Check the input power switch (S1) for proper operation. See the Wiring Diagram. 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. 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. 1-800-833-9353 (WELD). 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 Transformer Test. 1. Perform the Transformer Test. 2. Perform the Circuit Test. Low Auxiliary Voltage 3. Perform the Input Rectifier Test. 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 F-5 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION FUNCTION PROBLEMS All the status lights begin to blink within 5 seconds of power up. 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. 1. Perform the Primary Power Board Resistance Test and Capacitor Voltage Test. 2. Perform the Input Rectifier Test. 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 Transformer Test. 2. Perform the Trigger Circuit Test. 3. Perform the Gas Solenoid Test. 4. Perform the Torch Continuity and Solenoid Test. 5. The control board may be faulty. Replace. 6. The output power board may be faulty. Perform the Output Board Resistance Test. 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. 2. Perform the Circuit Test. Low Voltage 3. The output board may be faulty. Perform the Output Board Resistance Test. 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 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) F-6 POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION FUNCTION PROBLEMS 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.) 1. Perform the Torch Continuity and Solenoid Test. 2. Make sure the torch consumables are in place and in good condition. 2. The output board may be faulty. Replace. 3. Make sure the air flow is not restricted. The cutting arc starts but sputters badly. 1. Make sure the operating procedure is correct for the process. See the Operation section of this manual. 2. Make sure the work clamp is connected tightly to the workpiece. 3. The control board may be faulty. Replace. 1. Perform the Torch Continuity and Solenoid Test. 2. The output board may be faulty. Replace. 3. The control board may be faulty. Replace. 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.) 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 PROBLEMS (SYMPTOMS) F-7 Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION CUTTING PROBLEMS The pilot arc is normal, but the arc will not transfer to the workpiece. 1. Make sure the operating procedure is correct for the process. See the Operation section of 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. Perform the Output Board Resistance Test. 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 TROUBLESHOOTING & REPAIR F-8 Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) RECOMMENDED COURSE OF ACTION POSSIBLE AREAS OF MISADJUSTMENT(S) LED FUNCTION PROBLEMS The Air Low LED is lit. 1. Make sure there is at least 70 psi (448 kPa) of air pressure connected to the gas connection at the back of the PROCUT 80. 1. The pressure switch (S5) or associated leads may be faulty. See the Wiring Diagram. 2. The control board may be faulty. Replace. 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). The Safety LED is flashing. 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. 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. The Safety LED is lit and steady. 1. Press the reset button. If the torch and consumables are properly installed, the Safety LED should turn off. 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 TROUBLESHOOTING & REPAIR F-9 Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) RECOMMENDED COURSE OF ACTION POSSIBLE AREAS OF MISADJUSTMENT(S) LED FUNCTION PROBLEMS The Thermal LED is lit. 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). 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-10 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. • Do not touch electrically hot parts. • Prior to performing preventative maintenance, perform the following capacitor discharge procedure to avoid electric shock. DISCHARGE PROCEDURE 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) 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. 1. Turn off input power and disconnect input power lines. 7. 2. Remove the 5/16" hex head screws from the wraparound machine cover. 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. 3. Be careful not to make contact with the capacitor terminals located at the bottom of the Input Power Board. Repeat the discharge procedure for the capacitor on the other two terminals. FIGURE F.1 – LOCATION OF INPUT FILTER CAPACITOR TERMINALS POWER BOARD CAPACITOR TERMINALS POWER RESISTOR RIGHT SIDE OF MACHINE INSULATED GLOVES PRO-CUT 80 INSULATED PLIERS 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). 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-12 F-13 F-13 TROUBLESHOOTING & REPAIR INPUT RECTIFIER TEST (continued) 1. Remove main input power to the machine. 4. With the phillips head screw driver, remove leads #207, 207A and #209 from the rectifier. 2. Perform the Input Filter Capacitor Discharge Procedure detailed earlier in this section. 5. Use the analog ohmmeter to perform the tests detailed in Table F.1. See the Wiring Diagram. TEST PROCEDURE 3. Locate the input rectifier (D1) and lead locations. See Figure F.2. Carefully remove the silicone sealant from leads #207, #207A, and #209. FIGURE F.2 – INPUT RECTIFIER AND LEADS C #207A B #207 A #209 TOP VIEW PRO-CUT 80 F-14 TROUBLESHOOTING & REPAIR F-14 INPUT RECTIFIER TEST (continued) TABLE F.1 INPUT RECTIFIER TEST POINTS TEST POINT TERMINALS +Probe A B C ANALOG METER X10 RANGE - Probe 207 207 207 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 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. PRO-CUT 80 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 Figure F.2. 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). 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-15 F-16 TROUBLESHOOTING & REPAIR PRIMARY POWER BOARD RESISTANCE TEST AND CAPACITOR VOLTAGE TEST (continued) FIGURE F.3 – PRIMARY POWER BOARD REMOVAL Primary power board with input filter capacitors PRO-CUT 80 POWER G3440 - 1 F-16 204 205 201 208 + + 203 206 207 202 CAPACITOR (C1) CAPACITOR (C2) TERMINALS TERMINALS TEST PROCEDURE 1. Remove main input power to the PROCUT 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. PRO-CUT 80 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 test outlined in Table F.2. F-17 TROUBLESHOOTING & REPAIR F-17 PRIMARY POWER BOARD RESISTANCE TEST AND CAPACITOR VOLTAGE TEST (continued) TABLE F.2 PRIMARY POWER BOARD RESISTANCE TEST POINTS TEST POINT TERMINALS ANALOG METER X10 RANGE + Probe - Probe Acceptable Meter Readings 201 207A 207A 201 Greater than 1000 ohms Less than 100 ohms 204 207A 207A 204 Greater than 1000 ohms Less than 100 ohms 202A 204 204 202A Greater than 1000 ohms Less than 100 ohms 202A 201 201 202A Greater than 1000 ohms Less than 100 ohms 205 203A 203A 205 Greater than 1000 ohms Less than 100 ohms 208 203A 203A 208 Greater than 1000 ohms Less than 100 ohms 206 208 208 206 Greater than 1000 ohms Less than 100 ohms 206 205 205 206 Greater than 1000 ohms Less than 100 ohms 6. If the power board does not meet the acceptable readings outlined in Table F.2, the board is faulty. Replace. See Power Board Removal and Replacement Procedure. 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. NOTE: Complete power board and filter capacitor replacement is recommended. 8. Carefully reconnect leads #201, #204, #205, and #208 to their appropriate terminals. Torque To 75 IN. LBS. PRO-CUT 80 F-18 TROUBLESHOOTING & REPAIR F-18 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. 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. 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 power board. See Figure F.3. • 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. 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 TROUBLESHOOTING & REPAIR F-19 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). 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-20 F-21 F-21 TROUBLESHOOTING & REPAIR OUTPUT POWER BOARD RESISTANCE TEST (continued) FIGURE F.4 – OUTPUT POWER BOARD LEAD LOCATIONS G3439 PRO-CUT 80 OUTPUT + X2 (B11) C13 X4 (B12) TEST POINT D25 LED3 LED5 (B21) LED1 LED4 LED2 TEST POINT D29 J33 X20 X40 J31 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. PRO-CUT 80 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. F-22 F-22 TROUBLESHOOTING & REPAIR OUTPUT POWER BOARD RESISTANCE TEST (continued) TABLE F.4 - OUTPUT POWER BOARD RESISTANCE TEST POINTS CIRCUIT OR COMPONENT(S) BEING TESTED +Probe J33-Pin4 to –Probe Terminal X2 Diode A1 and associated trace Less than 100 ohms +Probe Terminal X2 to –Probe J33-Pin4 Diode A1 and associated trace Greater than 1000 ohms +Probe J33-Pin4 to –Probe Terminal X4 Diode A1 and associated trace Less than 100 ohms +Probe Terminal X4 to –Probe J33-Pin4 Diode A1 and associated trace Greater than 1000 ohms +Probe D29 Test Point to –Probe Terminal X20 Diode A2 and associated trace Less than 100 ohms +Probe Terminal X20 to –Probe D29 Test Point Diode A2 and associated trace Greater than 1000 ohms +Probe D29 Test Point to -Probe Terminal X40 Diode A2 and associated trace Less than 100 ohms +Probe Terminal X40 to –Probe D29 Test Point Diode A2 and associated trace Greater than 1000 ohms +Probe D29 Test Point to –Probe J32-Pin14 Transistor A2 and associated trace Less than 100 ohms +Probe J32-Pin14 to –Probe D29 Test Point Transistor A2 and associated trace Greater than 1000 ohms 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 Procedure. EXPECTED RESISTANCE 8. Carefully reconnect the leads and plugs previously removed. Torque X2, X4, and B21 to 75 IN. LBS. 7. If the output power board “passes” the resistance test, the power diode and transistor portion of the board is good. However, other circuits on the power board may be faulty. These circuits are NOT readily tested or serviceable. PRO-CUT 80 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). 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-23 F-24 F-24 TROUBLESHOOTING & REPAIR TORCH CONTINUITY AND SOLENOID TEST (continued) FIGURE F.5 - TORCH CONNECTOR - MACHINE END 8 7 6 9 4 1 5 3 2 TEST PROCEDURE 3. Using the ohmmeter, check the torch resistances per Table F.5. 1. Remove input power to the PRO-CUT 80 machine. NOTE: Take the “Pin” test point measurements at the machine end of the torch assembly. See Figure F.5. 2. Remove the torch assembly from the machine. TABLE F.5 - TORCH ASSEMBLY RESISTANCES TEST POINTS CIRCUIT(S) BEING TESTED EXPECTED RESISTANCE TEST CONDITIONS Pin 7 to Pin 8 Parallel pilot arc leads 1.5 ohms maximum None Pin 7 to Torch Nozzle One pilot arc lead to nozzle 1.0 ohm maximum Torch consumables in place Pin 8 to Torch Nozzle One pilot arc lead to nozzle 1.0 ohm maximum Torch consumables in place Pin 1 to Pin 9 Torch trigger circuit 100K ohms minimum Torch trigger NOT pulled (not activated) Pin 1 to Pin 9 Torch trigger circuit 1.0 ohm maximum Torch trigger pulled (activated) Pin 2 to Pin 3 Electrode Solenoid 45 to 55 ohms None Pin 7 to Torch Electrode at machine end of torch Pilot and Electrode circuit 1.0 ohm maximum Torch consumables in place Pin 8 to Torch Electrode at machine end of torch 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). 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-25 F-26 F-26 TROUBLESHOOTING & REPAIR AIR/GAS SOLENOID TEST (continued) FIGURE F.6 – AIR SOLENOID 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 + X2 (B11) C13 X4 (B12) TEST POINT D25 LED3 LED5 (B21) LED1 LED4 LED2 TEST POINT D29 J33 X20 X40 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). 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-27 F-28 F-28 TROUBLESHOOTING & REPAIR (T2) AUXILIARY TRANSFORMER TEST (continued) FIGURE F.8 – T2 AUXILIARY TRANSFORMER 10 PIN D1 6 1 7 2 8 3 AUXILIARY TRANSFORMER 9 4 5 Plug J21 8 PIN H2 5 H4 7 H5 8 1 2 H3 4 H6 Plug 22 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. PRO-CUT 80 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 Figure F.8 and Table F.6.. F-29 TROUBLESHOOTING & REPAIR F-29 (T2) AUXILIARY TRANSFORMER TEST (continued) TABLE F.6 - J21 AND J22 VOLTAGES TEST POINT H1 H1 H1 Brown (8J21) Red (2J21) Blue (9J21) Blue (4J21) Yellow (1J21) TEST POINT H2 (5J22) H4 (7J22) H5 (8J22) Brown (3J21) Red (6J21) White (5J21) White (5J21) Yellow (7J21) 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. EXPECTED VOLTAGE 200 - 208VAC 380 - 415VAC 440 - 460VAC 12VAC 24VAC 18VAC 18VAC 115VAC 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). 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-30 F-31 F-31 TROUBLESHOOTING & REPAIR TRIGGER CIRCUIT TEST (continued) FIGURE F.9 – SIMPLIFIED TRIGGER CIRCUIT DIAGRAM SIMPLIFIED TRIGGER CIRCUIT OUTPUT BOARD CONTROL BOARD +17VDC +15VDC TORCH RECEPTACLE 9 TRIGGER SWITCH IN TORCH HANDLE 1 #4 1J31 #2 2J31 D25 AUX 3J32 #344 11J3 14J32 #312 12J3 COM 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. Locate the torch cable receptacle and leads #2 and #4. See Figure F.9, the Simplified Trigger Circuit Diagram. These leads are best accessed at plug J31 on the output board. See Figure F.10. 4. Using the ohmmeter, check for continuity (less than one ohm) from lead #2 to lead #4. The torch trigger must be pulled and all input power removed from the machine. If continuity (less than one ohm) is not read, check the leads from plug J31 to the torch cable receptacle. Perform the Torch Continuity and Solenoid Test. 5. If less than one ohm is read (only when the torch trigger is pulled), proceed to the next step. Also see Output Board LED Definitions and related figures. 6. Apply the correct input power to the PROCUT 80. Carefully check for approximately 17 VDC from plug J31 pin-1(lead#4) (positive) to plug J31 pin-2 (lead#2) (negative). See Figure F.10. If the correct voltage is not present, perform the Low Voltage Circuit Test. Also see Output Board LED Definitions and related figures. PRO-CUT 80 P R O C E S S O R COM 7. If the correct voltage is present in Step 6, carefully check for the presence of approximately 15 VDC from plug J32 pin-3 (lead#354) (positive) to plug J32 pin-14 (lead#312) (negative). See Figure F.10. Also see Control Board LED Definitions and related figures. If the correct voltage is not present, perform the Low Voltage Circuit Test. 8. If the correct voltage is present in the above test, carefully pull the torch trigger. WARNING PILOT ARC, CUTTING ARC, AND HIGH VOLTAGE MAY BE PRESENT AT THE TORCH HEAD. Perform this test with the air input removed to avoid a pilot arc at the torch. 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 Discharge Procedure. 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 Figure F.10. 12. If all of the above checks are OK, the control board may be faulty. Replace. PRO-CUT 80 F-32 F-33 F-33 TROUBLESHOOTING & REPAIR TRIGGER CIRCUIT TEST (continued) FIGURE F.10 - OUTPUT BOARD TRIGGER CIRCUIT TEST POINTS AND LEDS G3439 PRO-CUT 80 OUTPUT + X2 (B11) C13 X4 (B12) TEST POINT D25 LED3 LED5 (B21) LED1 LED4 LED2 TEST POINT D29 J33 X20 X40 J31 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. 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. 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. 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.) 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 F-34 TROUBLESHOOTING & REPAIR TRIGGER CIRCUIT TEST (continued) FIGURE F.11 - CONTROL BOARD LEDs PRO-CUT 55 CONTROL G3328 PRO-CUT 80 CONTROL G3443 LED2 LED1 LED3 CONTROL BOARD LED DEFINITIONS LED1: (Red) This light indicates that 18 VAC is being supplied to the control board from the auxiliary transformer. 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-34 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). 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-35 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 12VAC BROWN 8 #53 3J30 BROWN 3 #56 6J30 RED =17VDC 17 VDC PLASMA OUTPUT BOARD H2 24VAC 2 #51 1J30 RED 6 #54 4J30 BLUE 4 #61 1J1 =28VDC 32 VDC H3 TO RECONNECT LEAD "A" H4 H5 18VAC 6J2 =+15VDC 18VAC WHITE 5 #62 2J1 BLUE 9 #64 4J1 #216 + +15VDC CONTROL BOARD =-15VDC 15J40 9J2 #219 10J40 D I S P L A Y B O A R D J21 PROCEDURE 1. Remove input power to the PRO-CUT 80 machine. 5. Check for the presence of 17 VDC on the output board. 2. Using the 5/16" nutdriver remove the case wraparound cover. 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. WARNING ELECTRIC SHOCK can kill. • Do not touch electrically hot parts. b. To verify the presence of 17 VDC, check from plug J31 Pin-6 to diode D25 (anode). See Figure F.13. Make certain the voltmeter probes make good contact with pin6 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. 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. PRO-CUT 80 a. LED1 should be lit when +15 VDC is present. See Figure F.13. See Control 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 present. See Figure F.13. See Control Board LED Definitions and Figure F.12, Low Voltage Circuit Diagram. 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 present. See Figure F.14. See Control Board LED Definitions and Figure F.12, Low Voltage Circuit Diagram. 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 Diagram. 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 Circuit Diagram and (T2) Auxiliary Transformer Test. 11. When the test is complete, remove input power and replace the case wraparound cover. PRO-CUT 80 F-37 F-38 F-38 TROUBLESHOOTING & REPAIR LOW VOLTAGE CIRCUIT TEST (continued) FIGURE F.13 – OUTBOARD LOW VOLTAGE CIRCUIT TEST POINTS AND LEDs G3439 PRO-CUT 80 OUTPUT + X2 (B11) C13 X4 (B12) TEST POINT D25 LED3 LED5 (B21) LED1 LED4 LED2 TEST POINT D29 J33 X20 X40 J31 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. 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. 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. 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). 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 F-39 TROUBLESHOOTING & REPAIR F-39 LOW VOLTAGE CIRCUIT TEST (continued) FIGURE F.14 – CONTROL BOARD LEDs PRO-CUT PRO-CUT80 55CONTROL CONTROLG3443 G3328 LED2 LED1 LED3 CONTROL BOARD LED DEFINITIONS LED1: (Red) This light indicates that 18 VAC is being supplied to the control board from the auxiliary transformer. 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 L10721 DISPLAY BOARD (REAR VIEW) J 40 15 1 #216 #219 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). 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-40 F-41 TROUBLESHOOTING & REPAIR F-41 CONTROL BOARD REMOVAL AND REPLACEMENT (continued) FIGURE F.16 - CASE FRONT SCREW REMOVAL 4 Screws PROCEDURE 1. Remove input power to the PRO-CUT 80 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 TROUBLESHOOTING & REPAIR F-42 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. 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 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. 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). 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-43 F-44 TROUBLESHOOTING & REPAIR F-44 DISPLAY BOARD REMOVAL & REPLACEMENT (continued) FIGURE F.19 - CASE FRONT SCREW REMOVAL 4 Screws PROCEDURE 1. Remove the input power to the PRO-CUT 80 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. PRO-CUT 80 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. F-45 TROUBLESHOOTING & REPAIR F-45 DISPLAY BOARD REMOVAL & REPLACEMENT (continued) FIGURE F.20 – DISPLAY BOARD REMOVAL DISPLAY BOARD CASE FRONT 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. 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. 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. 10. Carefully reposition the front assembly in place and install the four mounting screws previously removed. 7. Depress the locking tab and remove the plug connector from the display board. 12. Using the 5/16” nut driver, install the case wraparound. PRO-CUT 80 11. Inspect, clear and secure all leads in preparation for the case wraparound reassembly. F-46 TROUBLESHOOTING & REPAIR OUTPUT POWER BOARD REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid 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-46 F-47 TROUBLESHOOTING & REPAIR F-47 OUTPUT POWER BOARD REMOVAL & REPLACEMENT (continued) FIGURE F.21 – OUTPUT POWER BOARD REMOVAL OUTPUT POWER BOARD PROCEDURE 1. Remove input power to the PRO-CUT 80 machine. 2. Remove the case wraparound and perform the Input Capacitor Filter Discharge Procedure detailed earlier in this section. PRO-CUT 80 3. Locate the output power P.C. board and associated lead and plug connections. See Figures F.21 and F.22. F-48 F-48 TROUBLESHOOTING & REPAIR OUTPUT POWER BOARD REMOVAL & REPLACEMENT (continued) FIGURE F.22 – OUTPUT BOARD LEAD LOCATIONS G3439 PRO-CUT 80 OUTPUT + X2 (B11) C13 X4 (B12) TEST POINT D25 LED3 LED5 (B21) LED1 LED4 LED2 TEST POINT D29 J33 X20 X40 J31 J34 J32 J30 4. Using the 7/16” wrench, remove leads X4, X2 and B21 from the output power board. 9. Carefully remove the output power board from the heat sink. 5. Remove plugs J30, J31, J32, J33, and J34 from the output power board. CAUTION 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. PRO-CUT 80 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. 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. PRO-CUT 80 F-49 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). 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-50 F-51 TROUBLESHOOTING & REPAIR F-51 PRIMARY POWER BOARD AND FILTER CAPACITOR REMOVAL AND REPLACEMENT (continued) FIGURE F.23 – PRIMARY POWER BOARD REMOVAL Primary Power Board With Input Filter Capacitors REMOVAL PROCEDURE 1. Remove input power from the PRO-CUT 80 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. PRO-CUT 80 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. F-52 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) 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. PRO-CUT 80 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. F-53 TROUBLESHOOTING & REPAIR F-53 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. PRO-CUT 80 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. F-54 TROUBLESHOOTING & REPAIR INPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid 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-54 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. 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. 4. Identify and mark the leads connected to the rectifier terminals. C #207A B #207 A #209 TOP VIEW FIGURE F.25 – INPUT RECTIFIER LEAD LOCATIONS PRO-CUT 80 F-56 TROUBLESHOOTING & REPAIR F-56 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 IDLE AMPS AND WATTS Input Volts/Hertz Idle Amps Idle Watts 208/230/460 0.61 140 Output Current Range 35 - 85 Amps Maximum Open Circuit Voltage 335 Volts PRO-CUT 80 F-58 NOTES PRO-CUT 80 F-58 G-1 ELECTRICAL DIAGRAMS G-1 TABLE OF CONTENTS -ELECTRICAL DIAGRAMS SECTIONELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION G WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-2 CONTROL PC BOARD SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-3 CONTROL PC BOARD ASSEMBLY - CODE 10574 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-4 CONTROL PC BOARD ASSEMBLY - CODE 10577 & 10578 . . . . . . . . . . . . . . . . . . . . . . . . . . G-5 POWER PC BOARD SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-6 POWER PC BOARD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-7 OUTPUT PC BOARD SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-8 OUTPUT PC BOARD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-9 DISPLAY PC BOARD SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-10 DISPLAY PC BOARD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-11 PRO-CUT 80 G-2 G-2 ELECTRICAL DIAGRAMS WIRING DIAGRAM - PRO CUT 80 RIGHT SIDE OF MACHINE P_XFMR 6 3 503 507 I xxxxxxx 404 T3 18V H5 8 18V U 9 64 W 5 62 U 4 61 Y 1 FAN 7 FAN H6 4 J22 S1 115V I U T Y Y XFMR -O -I R S 2 206 F 3 2 R K -O X3 -I W 365 J34 N.C. J32 8 AIR SOL 2 ELEC SOL 3 TRIGGER 13 IGBT 14 GND A 0.6A SLOW BLOW H3 220230V J30 1,4 24V OUTPUT 12V L1 CHOKE S 6 1 7 2 8 3 9 4 10 5 369 364 R -O U 277B 277A 216 15 +15V 217 14 READY LED 212 13 LOW_PSI LED 18V 18V 218 12 POT WIPER 404 401 1 2 7 3 343 8 4 344 1 2 10 3 11 4 12 5 13 6 14 7 4 1 5 2 6 3 T U B 213 11 RESET 4 219 10 GND 3 7 P_XFMR 214 9 THERMAL LED 2 6 ++VOLT 1 5 RELAY J1 6 2 5 1 4 CT TSTAT 1 7 2 8 3 9 4 10 5 NN 360 W 8 16 R 7 15 X40 X4 312 360 354 E 310 R 303 302 309 218 219 210 5 213 276 4 214 223 3 215 277 2 7,8 ELEC SHUNT (TWIST PR) R1 10K 2W 277 277A CONTROL A 347 B CONTROL POT CW (MAX) D C E F G DISPLAY I J K H L M N INTERFACE RECEPTACLE J20 310 306 2 303 302 312 53 J40 276 354 54 RESET LED PSI SET 1 221 275 348 309 7 275 5 13 4,5 XFER SHUNT (TWIST PR) 4 12 12 GND 11 TRIGGER 3 11 3 IGBT 2,6 PSI SWITCH 2 10 10 ELEC SOL 1 9 9 AIR SOL W 8 215 212 6 14 306 210 6 216 217 J2 1 W S5 Y PRESSURE 4 R WORK 361 AIR 366 SOLENOID W 51 N 56 7 N 4 369 9 1 xxxxxxx 4 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 3 LEFT SIDE OF MACHINE OUTPUT BASE CASE FRONT PC BOARD PROTECTIVE BONDING CIRCUIT COLOR CODE: B = BLACK G = GREEN R = RED W = WHITE U = BLUE N = BROWN Y = YELLOW 364 5 E 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 8 6 E 401 NOTES: 6 K -O 2 3 J3 365 4A 2A 5 8 2 1 8 3 X20 X30 223 221 J21 J4 Y Y T 361 6 9 4 366 505 RESET J5 X2 N B J31 1,2 TRIGGER 4 ELECTRODE 3 NOZZLE 5,6 AIR SOL 7,8 ELEC SOL 10 WORK SHOWN FOR 400-460VAC OPERATION K -I N 206 S A S X20 B21 506 X10 X40 X2 507 W S B X1 N 201 -I F U T W 4 XFER 7 K ELEC 1 R B XFER 205 J33 ELEC 3 R S X4 202 H5 501 S + 6 C2 3000/450 502 N S FR - 503 B S F 207 S2 S3 PSI_SET 4 MAIN 204 C POWER B A T1 208 CURRENT TRANSFORMER 202 207A REAR OF MACHINE 54 61 201 204 203 H4 7 J10 202 440- 51 6 AUXILIARY TRANSFORMER T2 506 203 460V 2 R Y 505 S4 PRIMARY RECONNECT 415V R 24V H4 B U FRONT OF MACHINE 502 56 4A 501 2 3 V 2A 1 5 RELAY N R W W 344 4 ++VOLT 53 H3 2 A A 207A 380- A 8 62 - FAN MOTOR 208V TP2 205 FAN POWER 200- + D 209 209 B TP3 G N 347 + 206 FAN H2 B BRIDGE 208 A D1 INPUT 5 C TP1 E C1 3000/450 FAN C 12V H2 348 F 207 203 H1 H1 343 - 207A 64 INPUT PER N.A. 2 J40 1 15 J2,J21,J31 J3 1 8 1 5 9 16 6 10 J1,J20 J33 1 2 J4,J10, J30 1 J5,J22, J34 J32 3 1 4 1 7 6 5 8 8 14 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. ELECTRICAL SYMBOLS PER E1537 3 4 4 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. PRO-CUT 80 G-3 ELECTRICAL DIAGRAMS SCHEMATIC - CONTROL PC BOARD +15V Vct = 0.01 Ip J4 COM PB7 35 ELECTRODE_SOLENOID CONTROL_POT 47 PE2 PA7 27 PRIMARY_POWER /PURGE 12 PC3 PB0 42 READY PC0 PB1 41 SAFETY AIR_LOW THERMAL PB3 PE0 PB4 38 PE3 PE4 44 15 PC6 PA1 33 45 PE1 PA0 34 32 PA2 PD0 20 3.74K 36 PB6 PD1 21 R100 40 PB2 MODA 3 4 SDI VDD 3 CLK VOUT 6 /LD 2 1 MS-001BA 11 23 PD3 (MOSI) PE5 46 24 PD4 (SCK) PE6 48 25 PD5 (CS_D/A) PE7 50 Vdd PA3 31 68HC711E9 R183 R188 5.1V 1W R41 10.0 3 INPUT 2 INPUT 4 OP27 8 5 10K R28 6 3.32K X1 LT1014 0.1 5 7 X16 221 221 R26 R30 C37 243 243 /PIP THERMAL D R170 MACHINE OVERVIEW +15V +5.5V -15V R16 1.30K D9 R177 R175 R9 511 50V R10 R8 1.00K 0.1 R176 OUT R7 GND 2.00K S18395-13 ASSY ADJ CUT DIODES C72 475 1.30K CUT WINDINGS C1 3300 C71 C3 50V 50V 18VAC 15J 0.1 1000 50V 35V NOTE: SOME OR ALL OF THESE RESISTORS MAY NOT BE PRESENT C7 TP2 C9 50 X9 IN J1 D8 27 GND 50V POWER SUPPLY 35V LED1 C5 LED2 LED3 WORK 100 50V J1 50V 4 IN S18647 ASSY J1 1 2 X8 OUT 3.92K XFMR 7805 X7 D1 AUX 18VAC COM R +5.5V D6 LM350 IN D2 50V C31 COM 5W R1 CT C17 +15V R6 R85 5.11K 1.0 15J R46 COM R32 2.67K J3 7 10.0K O J2 TRANSFER SHUNT 10.0K 1V = 12.50 A 50V B A R84 TP1 GAIN = 80.0 4 R24 AIR_LOW 4 3.32K 2700p SENSE_AUX TCF6000 R35 Y J2 R118 D5 COM CW 6 NC PIP A 2 50V COM R40 7 OUT .47 D23 L 10 3.32K COM R5 R194 V CC X4 V EE 10.0K 7 S C45 COM ELECTRODE 10.0K C16 SHUNT ELECTRODE C36 6 C4 6.19K R18 R36 243 R27 R33 R80 X3 READY I J2 3.32K R117 50V 100K POWER SUPPLY X16 D 7 J2 30V 150p 5 LM224 1V = 68.07mA R81 3.92K 3.92K R193 J3 8 NULL 14 5 12 COM NULL R21 33.2K LT1014 R192 COM 100K X1 1.0A R89 TCF6000 R83 150p 50V 13 R78 1K 1 221K C22 CW 243 1.30K 221K 1.21K PRE-CHARGE DISABLE R116 D21 C44 R82 R79 G R109 R98 8 9 50V COM +15V J5 Q4 4A 100V P 28.0K .47 COM 1400V D 3.32K 8.25K R103 R48 C18 COM COM COILS 1 5 10.0 R115 619 D14 1.50K 12 X1 LT1014 R73 LT1014 R197 6.81K 2.43K 10 R88 1 100K 6 +15V 243 J3 RELAY J5 .0047 D20 V_PWM 1.00K 1.00K 3 1.00K COM R93 R37 C35 R111 R64 30.1 X1 C53 OP27 10.0K COM R38 10.0 1 R4 7.68K R72 243 J3 4 -15V 10.0 R110 50V COM 15.0K R25 COM TCF6000 47.5K 2 0.1 50V R171 +15V 39.2K C29 1.0 DZ3 2 R60 R3 511 R96 1.00K X16 8 X3 243 5 511 R42 R87 ELECTRODE SOLENOID 33074A LM224 2.67K NC 33.2K 3.92K R15 R70 X2 9 10 R97 V EE 50V 7 6 150p C43 8 OUT OPTOCOUPLER 4.75K SENSE_AUX S 82.5K V CC X6 10 J3 100K 3 R2 INPUT 2N4401 D24 R196 COM R191 INPUT 4 R94 10.0K C15 3 2 -15V Q3 COM COM ELECTRODE_AMPS R34 C47 SHUNT TRANSFER 243 R39 IGBT DRIVE R91 PRIMARY_POWER 3.92K R190 243 J3 5 OPTOCOUPLER 4.75K 825 22 PC2 26 COM +15V 47.5K PD2 (MISO) R67 47.5K PC4 49 PB5 3 J3 D22 43 AS 2N4401 ELECTRODE_SOLENOID /PIP 37 Q2 R58 SENSE_AMPS /CLR -15V 3.74K 39 VREF 7 47.5K PC5 15.0K SENSE_AMPS C11 +15V R189 BOARD s15018-19k1 R139 R138 14 R29 1K NULL s15018-19k1 R131 12.1K PILOT_SWITCH X15 AIR SOLENOID 825 AIR_SOLENOID 13 OPTOCOUPLER 4.75K +15V COM 17 PILOT_SWITCH X5 9 J3 D19 AIR_SOLENOID 9 2N4401 C6 COM CW NULL Q1 R172 R149 5.11K COM COM +15V 1 825 R102 3.74K 5 COM OUTPUT 10.0K R135 15.0K R187 2.67K R113 1.00K 100V /OUTPUT GND 8 10.0K 50V COM +15V 10K 126 Amps = 0.35V 330p 15.0K C70 .0047 50V R101 4.75K EXTAL /RESET R61 R174 68.1K +5.5V 8 7 4 9 V+ ISINK XTAL LM2907 35V J5 2 COM 10 IBIAS 0.1 35V COM CW 90 Amps = 0.25V C48 10.0K Ic 5 51 E 8 R184 NC 2 GND D13 3A 40V C33 COM 10.0K NC 7 2 3 C62 1.0 COM R179 C40 6 7 J5 5 INV IN C14 R106 C67 1.0 COM 28 3 5 VRL /XIRQ R104 C38 6 R50 50K 1.21K OUT Vin + Vc COM 29 +5.5V 33074A 1.00K R159 R173 J5 6 9 R23 7 ISOURCE IBIAS 10.0K 8 X2 10.0K X16 12 R107 4 CW TCF6000 13 NC GND 7.68K COM 14 NC X17 R182 / R77 PRIMARY CAP OPTOCOUPLER TACH INPUT 52 R/W R69 10 TACH INPUT 1W 4 20V 30 /RETRACT_ARC X16 3 12V C61 1.8 PA6 ELECTRODE_AMPS TCF6000 1 DZ2 COM 10.0K R57 5.11K COM +5.5V 11 3 PA5 PRIMARY VOLTAGE 10.0K 1W PA4 /PSI_OK R160 12V PC7 /PSI_OK 10.0K DZ1 1 PC1 THERMOSTAT OK COM VRH /IRQ /SAFETY_RESET R158 12 2 1 N.I. IN X14 16 10.0K 35V 1.30K D12 3A 40V 267 13 10 TRIGGER R178 COM C30 1.0 J3 CS- COM R141 10 NOTE: +5.5V R180 OPEN = OVERTEMP = L X10 R56 6 2 RT N.I. IN J5 D11 3A 40V R140 14 UC2856N Shutdown Condition: 10.0K R19 SHORT = TEMP OK = H 5.11K 13 C13 COM PRESSURE SWITCH CL SS PULSE XFMR 3 1 COM MODB 18 10.0K 4 7 GND VREF SHUTDOWN COM 2 INV IN 2 5.62K Vss 19 R17 14 TCF6000 100 CT EA+ 1 Q5 RES R68 X3 LM224 10.0K J3 3.32K 10.0K 6 12 1 2 R43 4.75K X10 COM R13 332 R136 TCF6000 R167 R164 R44 R166 221K J4 R137 Vss COM 4.75K 332 R14 +5.5V Vc EA- 11 GATE DRIVE 3 GND R99 R12 332 R112 S-8054HN 100V 10.0K R165 332 PSI 100V 10.0K J4 SYNC X12 3.32K +5.5V 35V 1 9 BOUT .018 2N4403 X11 10p 10p THERMOSTAT(S) 50V C12 AOUT CS+ COMP R133 C28 1.0 R11 16 R132 COM 4.75K Vdd C46 C52 +15V 5 V_PWM .018 VIN 50V 4 OUT D10 3A 40V 0.1 5 Vin + Vc X13 COM 10.0K R129 /SAFETY_RESET COM 3 +5.5V 8.000MHz Y1 R114 TRIGGER OFF = L COM R195 TRIGGER ON = H RESET PUSHBUTTON 35V 50V R31 R54 3 C60 13 0.1 50V R181 R55 5.11K 5 8 12 X2 C58 COM 1.50K C39 X10 100V 33074A R156 1 2 100K TCF6000 100 J2 X3 LM224 +5.5V 4 10.0K 3 R153 100V 6 100p 14 X10 R108 COM D D25 J3 11 330p TCF6000 COM R63 OPTOCOUPLER +5.5V C27 10.0K 3.74K TRIGGER CIRCUIT 35V R 221K R62 O A R155 20.0K 10.0K C26 1.0 B R152 10.0K PURGE R76 OPEN = TRIGGER OFF 1.00M SHORT = TRIGGER ON R157 /PURGE 5.11K 2 R52 5 PUSHBUTTON TCF6000 100 J2 R154 7 C59 R130 R53 5.11K X10 R65 COM 10.0K 10.0 R142 10.0 R127 10.0 R128 R125 10.0 R126 10.0 R22 10.0 R124 15 4 COM 10.0K +15V C50 4.7 267 26.7 R122 COM 0.1 50V COM 4.75K 26.7 R121 D18 1N4936 35V 2.21K 125:1 D17 1N4936 C55 C54 1.0 35V 2.21K +5.5V C23 10.0 CURRENT XFORMER R123 PRIMARY C32 C42 C57 1.0 10.0K J2 9 Y 1N4936 10.0K A R47 C21 1.0 35V L CONTROL_POT R120 R45 P 1N4936 6 26.7 8 S MIN R49 J2 J4 3 100K I 10K CUTTING CONTROL POT C56 .15 100V TCF6000 100K 4.75K D D16 10.0 X10 J2 6 MAX D15 R20 LOCAL ... 26.7 SETPOINT +15V 3 CUTTING CURRENT R134 +15V COM CALIBRATION OUT NOZZLE PILOT WINDINGS -15V ELECTRODE SHUNT L1 7915 D3 COM PILOT DIODES D7 D4 COM +15V +15V +5.5V +5.5V FILENAME: G3353_1CA C68 7 C69 7 C63 4 C64 4 4 13 8 8 Vdd 26 C20 X6 OP27 COM C2 4 OP27 C8 X2 X1 X4 LT1014 COM C65 11 4 C66 C10 X3 33074A 11 X12 LM224 UC2856N 11 C19 C41 4.7 35V 12 COM 14 2 5 TO: DISPLAY SUPPLY 1 J1 TO: OUTPUT BOARD 2 1 J2 TO: CT & TSTATS BOARD 5 1 J3 TO: POWER 8 1 J4 1 J5 6 TCF6000 C24 X5 35V C34 68HC711E9 1 16 15 1 Vss 1 1 COM 6 10 9 16 4 6 5 N.A. COM MS-001BA GENERAL INFORMATION C49 12 LAST NO. USED R- ELECTRICAL SYMBOLS PER E1537 CAPACITORS = MFD ( .022/50V RESISTORS = Ohms ( 1A, 400V 1/4W C- UNLESS OTHERWISE SPECIFIED) UNLESS OTHERWISE SPECIFIED) (UNLESS OTHERWISE SPECIFIED) 5 LABELS D- SUPPLY 197 X- 72 Q- 5 25 DZ- 3 17 Y- 1 TP- 2 LED- 3 VOLTAGE NET POWER SUPPLY SOURCE POINT REF. DESIGNATORS SKIPPED: R51,R59,R66,R71,R74,R75,R86,R90,R92,R95,R105,R119, COMMON CONNECTION FRAME CONNECTION EARTH GROUND CONNECTION NOTES : 33074A 4 8 X15 R143-R146,R150,R151,R161-R163,R168,R169,R185,R186 1 2 5 4 8 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 4 LM2907 C51 DIODES = 13 7 3 3 X17 7 J3 J3 J3 J3 J3 X2 BOARD 3 TCF6000 X10 -15V X16 POWER X16 9 C25 4.7 J1 J2 J4 J4 J5 J5 NUMBER. 3-19-99 G 3353 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. PRO-CUT 80 G-4 ELECTRICAL DIAGRAMS PC BOARD ASSEMBLY - CONTROL BOARD (CODE 10574 ONLY) ITEM REQ'D ) C1 1 ) C2,C8,C10,C11,C13,C14,C17 ) PART NO. DESCRIPTION ) S13490-92 ) 30 S16668-5 3300/50 ) .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 ) C4,C18 ) S13490-121 ) S13490-63 2 C5 ) 1 ) S13490-71 C6 ) 1 ) T11577-52 C7 ) 1 ) S13490-72 C9 ) 1 ) S13490-93 2 ) S13490-126 8 ) S16668-11 3 ) S13490-25 8 ) S13490-42 3 ) C12,C60 ) C15,C16,C32,C33,C42,C58 ) 1000/35 ) .47/50 ) 100/50 ) 50/50 ) .0047 or .005/1400 ) 27/35 ) .018/50V ) .1/50 ) 1.0/35 C71,C72 ) C19,C25,C50 ) C21,C26,C28,C30,C54,C57 ) 4.7/35 C62,C67 ) S16668-9 ) 2 ) S16668-8 ) C29 ) ) 1 ) S13490-135 C45 ) 1 ) S16668-4 2 ) S16668-13 ) C22,C43,C44 ) C27,C48 ) C46,C52 6.00 ~.04 150pF/100 330pF/100 ) 2700pF/50 C56 ) 1 ) S13490-108 ) C59 ) 1 ) S16668-3 ) C61 ) 1 ) S13490-19 C70 ) 1 ) ) D1,D2,D3,D4,D5,D6,D7,D8,D9 ) 16 1.0/50V ) 10pF/100 .15/100 100pF/100 ) S16668-10 ) T12199-1 ) 1.8/20 4700pF/50 1N4004 D14,D19,D20,D22,D23,D24 D25 ) D10,D11,D12,D13 R137 R178 R43 R68 R44 R108 Y1 C20 C55 C48 R195 R112 R114 DZ3 R183 R184 R149 R180 C58 C59 C27 R65 R131 R134 R129 R130 C61 C62 R135 R139 R141 R113 R55 R53 R77 1 ) S18248-16 ) HEADER J4 ) 1 ) S18248-6 ) HEADER J5 ) 1 ) S18248-8 ) HEADER 3 ) T13657-2 ) RED LED 3 ) T12704-68 ) ) ) ) 1 ) T12704-80 ) HEXFET TRANS. (SS) Q5 ) 1 ) T12704-69 ) 2N4403 R1 ) 1 ) T13165-16 ) 3 ) S19400-2671 ) 2.67K 1/4W 9 ) S19400-2430 ) 243 1/4W ) 30.1 1/4W ) 8.25K 1/4W ) ) 1.0 OHM, 5W RESISTOR R4 ) 1 ) S19400-30R1 R5 ) 1 ) S19400-6190 R6 ) 1 ) S19400-8251 5 ) S19400-3921 1 ) S19400-2001 ) 2.0K 1/4W 7 ) S19400-1001 ) 1K 1/4W ) ) ) ) ) 619 1/4W ) 3.92K 1/4W S19400-5110 ) 511 1/4W 4 ) S19400-3320 ) 332 1/4W 2 ) ) S19400-3322 ) 33.2K 1/4W S19400-1002 ) 10K 1/4W 3 ) ) ) ) 31 R63,R68,R69,R81,R84,R93 R140 R94,R104,R106,R108,R134 R138,R139,R154,R156,R158 R160,R164,R165,R166,R178 R179,R180,R181,R182 ) X14 R18 ) R19,R53,R55,R57,R85,R149 1 ) S24073-1 7 ) S19400-5111 ) 10K,1/2W,TRIMMER ) C23 C21 R45 R52 R54 ) R24,R35 C42 D10 R25,R47,R49,R80,R89,R153 C6 5.11K 1/4W ) S19400-10R0 10 1/4W 2 ) S19400-2210 ) 7 ) S19400-1003 ) ) 100K 1/4W ) 7 ) S19400-3321 ) 3.32K 1/4W 3 ) S19400-8250 ) 825 1/4W ) 1M 1/4W 221 1/4W R118,R133 R110 ) R29,R91,R102 R111 R197 ) R183 R28,R112,R115,R116,R117 D20 12 R196,R197 X13 J2 ) R125,R126,R127,R128,R142 R31 ) 1 ) S19400-1004 R40 ) 1 ) S19400-6191 4 ) S19400-1502 ) 15K 1/4W 9 ) S19400-4751 ) 4.75K 1 ) S19400-2802 ) 28.0K 1/4W 3 ) S19400-1000 ) 100 1/4W 4 ) S19400-3741 ) 3.74K 1/4W 2 ) S19400-2211 4 ) S19400-4752 ) 47.5K 1/4W ) S19400-1501 ) 1.5K 1/4W ) ) R41,R60,R135,R184 C32 R196 ) ) ) R58,R76,R99,R100 ) R65,R129 .25 0 ) R72,R195 ) R73,R107 ) 2 6.19K 1/4W ) R78,R159 ) R79,R83,R155,R167 9.00 ~.04 S19400-7681 ) 7.68K 1/4W ) S19400-1301 ) 1.3K 1/4W 2 ) S19400-1211 ) 1.21K 1/4W 4 ) S19400-2213 ) 221K 1/4W ) 1 ) S19400-8252 ) 82.5K 1/4W R98 ) 1 ) S19400-2431 ) 2.43K 1/4W R109 ) 1 ) S19400-6811 R114 ) 1 ) S19400-5621 ) 5.62K 1/4W 4 ) S19400-26R7 ) 26.7 1/4W 1 ) S19400-1212 ) 12.1K 1/4W 1 ) S16296-5 2 ) S19400-2670 ) 267 1/4W ) 20K 1/4W ) R131 ) R132 ) ) R140,R141 CAPACITORS = MFD/VOLTS INDUCTANCE = HENRIES RESISTANCE = OHMS 2.21K 1/4W R97 R120,R121,R122,R123 8.75 ) 4 2 ) R77,R82,R175,R177 8.15 ) R170,R171,R172 J5 0 ) R43,R44,R45,R130,R136,R137 R67,R70,R87,R101 .25 2N4401 Q4 R11,R12,R13,R14 R47 C40 R159 R115 R118 R117 C56 R121 R120 R122 R123 D17 D15 R125 R124 R21 R82 R152 R154 R155 C39 R153 D25 C13 R76 R13 R164 R14 C36 R33 C37 R32 C47 R39 R38 C35 D24 R172 Q3 R171 D22 Q2 D19 R170 HEADER ) R10,R42,R96 D12 D13 C28 C26 R109 R49 R116 R142 D18 R128 D16 R83 R127 C10 R167 R166 R156 R165 R157 R11 R12 R27 R36 R30 C16 R94 R34 C15 R37 R91 R100 R58 R101 R67 R29 R99 R87 R102 Q1 D2 TP2 D1 D11 C9 Q4 3.55 HEADER J3 R52,R54,R56 .85 1N4733A ) R113 DZ1 J4 ) ) R9,R15,R50,R64,R88,R103 C50 R17 J3 T12702-52 S18248-10 R48 J1 ) ) R20,R22,R110,R111,R124 R19 X3 1N4742A 1 R157 R20 R126 R15 R16 R25 R192 R194 R193 C8 C69 C2 C68 R26 R93 D8 D7 TP1 R106 R179 C64 C11 C1 X4 R85 R84 R23 R60 D14 X6 R104 R41 ) 1 R17,R23,R26,R27,R61,R62 R50 R64 T12702-19 R38,R39 C33 C18 ) ) R7,R190,R191,R193,R194 DZ2 1N5818 2 J2 R3,R30,R32,R33,R34,R36,R37 X12 R73 R18 R40 R46 R28 R72 C43 X2 1N4936 ) S18248-4 R16,R21 C17 C66 C63 C65 R70 C53 R42 R107 R88 R35 R191 R190 R189 X1 R96 C29 R103 R188 C41 C4 D23 R81 R89 R97 R80 D21 C31 R24 1N5822 SCHOTTKY BARRIER DIODE ) T12705-23 ) R2,R46,R187 C60 R63 C19 C34 C14 C25 C24 R57 R174 R158 C30 R187 C54 C57 R1 R48 X9 D3 R62 ) 1 Q1,Q2,Q3 R133 ) T12705-34 ) ) LED1,LED2,LED3 R61 T12705-37 ) 1 J1 R8 R98 C45 R22 LED3 C7 R177 X5 X16 R78 C22 R79 R182 C5 D5 C44 D4 R132 R136 Q5 LED1 3.75 R56 C72 D9 C71 R175 X7 R2 C3 R160 R181 C46 R3 ) DZ3 X15 X10 ) DZ1,DZ2 C12 R173 X17 X11 C52 R31 X8 C49 C38 R176 LED2 C51 R9 R10 R7 R8 R6 R4 R5 D6 C67 ) D21 4 4 ) D15,D16,D17,D18 G3443-1 C70 R138 PRO-CUT 80 CONTROL R69 5.75 ) 6.81K 1/4W ) 10K TRIMMER R152 ) 1 ) S19400-2002 R173 ) 1 ) T10812-39 R174 ) 1 ) S19400-6812 ) 68.1K 1/4W R176 ) 1 ) S19400-4750 ) 475 1/4W R188 ) 1 ) S19400-3922 ) 39.2K 1/4W 2 ) T10812-68 ) 1K 1/2W TRIMMER 2 ) T13640-15 ) 15J ) R189,R192 ) TP1,TP2 ) 50K 1/2W TRIMMER 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 3-19-99 G 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. 3443-1B3 PRO-CUT 80 G-5 ELECTRICAL DIAGRAMS PC BOARD ASSEMBLY - CONTROL BOARD (CODE 10577 & 10578 ONLY) 3 ITEM 3 C1 !%ÏG S13490-92 C2,C8,C10,C11,C13,C14,C17 PART NO. REQ'D !%ÏG G3560-1B3 1 DESCRIPTION 3300/50 30 S16668-5 .022/50 C20,C23,C24,C31,C34,C35 C36,C37,C38,C39,C40,C41 N.C. C47,C49,C51,C53,C55,C63 C64,C65,C66,C68,C69 C3 1 C4,C18 1 2 N.G. N.A. N.F. S13490-121 2 1000/35 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 C15,C16,C32,C33,C42,C58 8 .018/50V S16668-11 .1/50 C71,C72 C19,C25,C50 3 S13490-25 C21,C26,C28,C30,C54,C57 S13490-42 1.0/35 C62,C67 ~.04 C22,C43,C44 3 C27,C48 R108 R137 R31 R178 X11 C52 Y1 X15 C14 4 T12705-37 4 T12705-34 T12705-23 2 1N5822 SCHOTTKY BARRIER DIODE 1N4936 1N5818 T12702-19 1N4742A S18248-4 1 S18248-10 J3 1 S18248-16 J4 1 S18248-6 HEADER J5 1 S18248-8 HEADER C60 1 J2 X12 1 C58 C59 C27 R65 R131 R134 R129 R130 C61 C62 T12702-52 LED1,LED2,LED3 3 Q1,Q2,Q3 R135 R139 R141 R113 R55 R53 1N4004 J1 C48 R195 R112 R114 DZ3 R183 R184 R106 R149 R180 R77 1 Q4 3 1 1N4733A HEADER HEADER HEADER T13657-2 RED LED T12704-68 T12704-80 2N4401 HEXFET TRANS. (SS) Q5 1 T12704-69 2N4403 R1 1 T13165-16 1.0 OHM, 5W RESISTOR R2,R46,R187 3 S19400-2671 R3,R30,R32,R33,R34,R36,R37 9 2.67K 1/4W S19400-2430 243 1/4W R140 S19400-30R1 30.1 1/4W R5 1 S19400-6190 619 1/4W R6 1 S19400-8251 8.25K 1/4W R8 1 X14 C23 7 R10,R42,R96 3 R11,R12,R13,R14 S19400-5110 4 2 S19400-3320 S19400-3322 D10 D11 31 332 1/4W 33.2K 1/4W S19400-1002 10K 1/4W R94,R104,R106,R108,R134 3 C42 R138,R139,R154,R156,R158 R160,R164,R165,R166,R178 R179,R180,R181,R182 X13 1 S24073-1 R19,R53,R55,R57,R85,R149 10K,1/2W,TRIMMER 7 S19400-5111 5.11K 1/4W 12 S19400-10R0 10 1/4W R157 R20,R22,R110,R111,R124 R111 R125,R126,R127,R128,R142 R110 R197 1K 1/4W 511 1/4W R63,R68,R69,R81,R84,R93 R18 C6 3.92K 1/4W 2.0K 1/4W S19400-1001 R113 C50 D20 S19400-3921 S19400-2001 R17,R23,R26,R27,R61,R62 C21 R45 R54 R52 5 R9,R15,R50,R64,R88,R103 R47 C40 R159 R115 R118 R117 C56 R120 1 R7,R190,R191,R193,R194 D12 D13 C28 C26 R109 R49 R116 R142 D18 R128 D16 R122 R121 R123 D17 D15 R125 R124 R21 R82 R152 R154 R155 R4 R16,R21 C57 R20 R126 R15 R83 C10 X3 C39 R153 D25 C13 R76 R13 R164 R14 C36 4700pF/50 DZ3 DZ1 R127 R167 R166 R156 R165 R157 R11 R12 R27 R33 C37 R32 C47 R39 R38 C35 D24 R172 Q3 R171 D22 Q2 D19 R170 1.8/20 T12199-1 C55 C19 C34 R179 C11 R16 R25 R192 R194 X4 R193 C8 C69 C2 C68 R93 R26 R36 R30 C16 R94 R34 C15 R37 R91 R100 R101 R58 R67 R29 R99 R87 R102 16 C20 C64 R41 R60 Q4 Q1 S16668-10 R187 R85 R84 R23 R50 R64 D14 C9 D2 S13490-19 1 R63 DZ2 R17 TP2 1 C70 10pF/100 .15/100 100pF/100 R62 R19 D1 D3 TP1 D4 C61 DZ1,DZ2 C33 C18 D8 D7 N.F. R104 X2 C1 X6 S16668-3 D21 R133 R73 R18 R40 R46 R28 R72 C43 R70 R107 C66 C63 C65 R103 C53 R42 X9 C17 R35 R191 R190 R189 S13490-108 1 R38,R39 X1 R96 C29 S16668-13 1 C59 D15,D16,D17,D18 C54 R88 R24 R188 R22 R1 D21 C31 2 1.0/50V 2700pF/50 C56 D10,D11,D12,D13 N.F. R98 C45 R48 C7 R177 C44 LED3 C41 C4 D23 R80 R81 R89 R97 X16 R78 C22 R79 R182 C5 D5 S16668-4 D25 R61 C25 C24 C30 R57 R174 R158 X7 330pF/100 S13490-135 1 D14,D19,D20,D22,D23,D24 R132 R136 X5 X10 Q5 LED1 3.75 R56 C72 D9 R175 C71 R3 R2 C3 R160 R181 C46 150pF/100 S16668-8 1 C45 D1,D2,D3,D4,D5,D6,D7,D8,D9 C12 X17 R43 R68 C49 R173 C38 R176 X8 C51 R9 R10 R7 R8 R6 R4 R5 D6 C67 LED2 2 S16668-9 C29 C46,C52 G3560-1 C70 R138 PRO-CUT 80 CONTROL R44 5.75 R69 6.00 8 4.7/35 C32 R196,R197 R24,R35 R196 2 S19400-2210 R25,R47,R49,R80,R89,R153 221 1/4W 7 S19400-1003 100K 1/4W 7 S19400-3321 3.32K 1/4W R183 J1 J3 J4 J2 R28,R112,R115,R116,R117 J5 R118,R133 R29,R91,R102 .25 3 S19400-1004 1M 1/4W 1 S19400-6191 6.19K 1/4W 4 R43,R44,R45,R130,R136,R137 S19400-1502 9 15K 1/4W S19400-4751 4.75K R170,R171,R172 R48 1 S19400-2802 R52,R54,R56 3 R58,R76,R99,R100 N.E. 0 9.00 2 4 3.55 8.15 S19400-1501 1.5K 1/4W 2 S19400-7681 7.68K 1/4W 2 S19400-1211 4 4 THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC CO. AND IS NOT TO BE REPRODUCED, DISCLOSED OR USED THE LINCOLN ELECTRIC CO. 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 (" ")t TO AGREE WITH PUBLISHED STANDARDS. 221K 1/4W 1 S19400-8252 82.5K 1/4W 1 S19400-2431 2.43K 1/4W R109 1 S19400-6811 6.81K 1/4W R114 1 S19400-5621 5.62K 1/4W 4 S19400-26R7 R131 1 S19400-1212 R132 1 S16296-5 2 26.7 1/4W 12.1K 1/4W 10K TRIMMER S19400-2670 267 1/4W R152 1 S19400-2002 R173 1 T10812-39 R174 1 S19400-6812 68.1K 1/4W R176 1 S19400-4750 475 1/4W R188 1 S19400-3922 R189,R192 WITHOUT THE EXPRESS PERMISSION OF 1.3K 1/4W 1.21K 1/4W S19400-2213 R98 R140,R141 UNLESS OTHERWISE SPECIFIED TOLERANCE S19400-1301 R97 R120,R121,R122,R123 CAPACITORS = MFD/VOLTS INDUCTANCE = HENRIES RESISTANCE = OHMS 47.5K 1/4W 2 R79,R83,R155,R167 8.75 S19400-4752 R73,R107 R78,R159 .85 3.74K 1/4W 2.21K 1/4W R72,R195 R77,R82,R175,R177 .25 100 1/4W S19400-3741 S19400-2211 R67,R70,R87,R101 ~.04 28.0K 1/4W S19400-1000 4 R65,R129 NOTE: 825 1/4W 1 R40 R41,R60,R135,R184 0 S19400-8250 R31 2 TP1,TP2 2 20K 1/4W 50K 1/2W TRIMMER 39.2K 1/4W T10812-68 1K 1/2W TRIMMER T13640-15 X1 1 S15128-16 X2 1 S15128-18 X3 1 S15128-4 15J IC,LT1014,LINEAR INTEGRATED CIRCUIT IC,33074A,OP-AMP,QUAD,HIGH-PERF IC,LM224,OP-AMP Ch'ge. Sht. No. XA THE LINCOLN ELECTRIC CO. EQUIP. INVERTER WELDERS TYPE CLEVELAND, OHIO U.S.A. 3-19-99A SCALE DR DRS SUBJECT FULL DATE 2-9-99 CONTROL P.C. BD AS'BLY (CANADIAN) SHT. CHK REF. G3443-1 SUP'S'D'G NO. G 3560-1B3 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-6 ELECTRICAL DIAGRAMS SCHEMATIC - POWER PC BOARD 209 POSITIVE B209 INPUT RECTIFIER +15V CR2 3 X3 LM224 CR1 LM224 4 11 R1 R2 40 40 10W 10W R23 R24 R25 150K 150K 150K 40 10W CAPACITOR PRECHARGE 3 11 R4 CR1 40 5 6 4A 900V UNDERVOLTAGE R33 1 OCI1 DZ7 6 7 1W 4 6 50V 5 OCI3 1 CR2 CNY17-3V 22.1K CR1 2 6 2 FROM CONTROL BD. 1 1 J10 100V 15V 35V 4 1A 18 1.00M 44.2K 1 (RELAY DRIVE) 2 D20 Q3 C17 C16 1.0 R85 221K R28 150p 100K 5 RECONNECT 206 J10 R92 X1 2 C5 R97 PROTECTION D18 CNY17-3V 12V 1.00K +15V 5 100 Q1 150K 1.00K R27 10W C18 150p 50V 4 221K X1 5 R96 6 R95 C19 4.75K C8 R93 CR2 R3 4 R94 4 4 R26 +15V TEST D R14 10.0 DZ4 R19 R81 1K 1K 5W 5W 1K D2 1A .022 .022 2000V 2000V 1000V BLEEDER B205 R31 1K C1 TRANSFORMER PRIMARY 205 A2 PEAK DETECTOR RESISTORS 5W D15 DZ15 +15V C27 .22 .22 1000V 1000V 325VDC (NOMINAL) FILTER +15V E2 E1 D1 C2 1A C1 .022 .022 2000V 2000V GATE R46 10.0K R52 202A R119 1.00K 1.00K R70 G4 C11 .0047 10.0 50V R71 15V E4 E3 31.6K C14 1.0 35V 221K Q2 1A 100V E2 D9 E1 1A C24 C12 .022 .022 2000V 2000V V/F CONVERTER 1000V R78 1W +15V B204 C1 1K 1K 5W 5W 1K R76 TRANSFORMER A4 R98 R99 R100 R101 150K 332K 16.5K 6.19K 5W 204 6.19K R82 1W .0047 50V 10.0 G2 R60 G3 10.0 G4 R61 10.0 E3 E2 E1 D8 1A 1000V C25 C9 .022 .022 2000V 2000V R104 15.0K +15V +15V D22 1.0 R106 2.94K 5W 1W C20 0.27 Q4 1A 2 100V Q5 50V A3 E4 10.0K R111 150K R53 R73 PRIMARY 201 C1 1 X3 1A 3 100V R114 47.5K D24 R79 C10 C2 DZ14 2.00K R57 1.00K C3 R72 15V 1.00K R56 DZ8 1.00K R55 1.00K G1 2.00K DZ10 R59 R109 332K 2.21K C4 1W TEST E TRANSFORMER R58 6.2V 1K R108 150K PROTECTION RESISTORS 10.0 10.0 DZ9 15V OVERVOLTAGE B201 R62 1W BLEEDER 5W A1 TEST A 150K 1K 207 D7 14 12 6.19K R110 R107 R105 CAPACITOR R103 D21 D4 1.82K A3 (NOMINAL) R48 1000V 7.68K 1000V 325VDC 1 2 R51 .22 X1 5W FILTER R74 .22 R75 202 C29 7 6 13.7K 1K X3 X3 1.00M C28 15.0K 13 5 3 C1 R102 +15V R50 PRIMARY A1 D23 R77 R115 G3 R35 10.0 A4 10K DZ13 1.00K 221K C1 CW 1W C2 1W R116 1.00K R67 15V R66 DZ11 R69 G2 DZ12 C3 C4 12V G1 10.0 R65 (PWM DRIVE) 221K R68 6.2V 1W R118 R49 G4 BOARD 10.0K GATE 7 D16 C6 DZ16 RECONNECT 10.0 2 8 R90 TEST B R63 S4 22.1K 10.0 G3 6 CONTROL 50V J10 X1 R36 GATE 9 150p 10 9 S3 12 4 C15 R84 4 FROM 6 (VOLTAGE PROTECTION) 1.00M 10 S2 DRIVE J10 TO CONTROL BD. CNY17-3V 2 MISCONNECTION +15V RECONNECT R64 3 OCI4 203A G2 1 5 5 PROTECTION S1 R54 6 1 OVERVOLTAGE 1000V 3 J10 35V 562 PROTECTION C23 J10 1.00K 10K 3.32K 50V 27 24.3K R117 .0047 1W 35V 6 C21 3.32K E3 R40 27 221K R8 R7 R6 R5 E4 D3 D5 C7 8 REF 8 9 13 10.0K 8 R12 15V - A1 G4 10.0 DZ1 G1 GATE 1 X2 TL431 G3 R11 1.00K + 2.8K R112 1.00K 1.00K 1W C1 14 X1 2.21K 1.00K 15V 5 G2 10.0 DZ3 C2 R41 1W C3 C4 G1 R10 T1 TRANSFORMER PRIMARY 208 R9 10.0 6.2V R42 10.0 10 X3 B208 10.0 DZ2 R83 1.00M 12 6.19K R13 25V D6 5W 203 A1 150K 1K CAPACITOR A1 TEST C 150K C13 50 12V 1W R45 C26 5W 7.68K C1 R29 A1 R34 206 R43 R30 1K R38 10.0 5W R37 E1 R39 E2 R113 E3 C4 R89 E4 C22 R88 G4 22.1K G3 R22 50V 1W R80 R87 15V 10.0 R21 10.0 .0047 C1 C2 A2 221K DZ6 C3 G2 R91 R18 R17 R16 R15 1W C3 C4 G1 R20 R47 1.00K 221K 1.00K 1.00K R44 1.00K 15V 221K DZ5 R32 10.0 1W 221K 6.2V 15V 1W NEGATIVE 207A INPUT RECTIFIER 300 Volts = 1kHz (calibrated) dF = 9.5136 dV 3-19-99A G FILE NAME: G3518_1CA NOTE: 202,203,206,&207 BOLT ON WITH FILTER CAPS GENERAL INFORMATION NOTES : N.A. SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE LAST NO. USED ELECTRICAL SYMBOLS PER E1537 WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY CAPACITORS = NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE RESISTORS = Ohms ( NUMBER. DIODES = MFD ( .022/50V 1A, 400V 1/4W 3518 UNLESS OTHERWISE SPECIFIED) UNLESS OTHERWISE SPECIFIED) (UNLESS OTHERWISE SPECIFIED) LABELS R- 119 Q- 5 X- 3 C- 29 CR- 2 OCI- 4 D- 24 DZ- 16 T- 1 SUPPLY VOLTAGE NET POWER SUPPLY SOURCE POINT COMMON CONNECTION FRAME CONNECTION EARTH GROUND CONNECTION NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. PRO-CUT 80 G-7 ELECTRICAL DIAGRAMS PC BOARD ASSEMBLY - POWER BOARD ) ) C2,C3,C10,C11 ) C5,C15,C18 ) C6,C8,C19 ) C7,C21 ) C13 ~.04 ) C14,C16 9.00 D1 PRO-CUT 80 G3440-1 DESCRIPTION 4 ) S20500-7 ) .047/1600 4 ) S16668-6 ) 4700pF/50 3 ) S16668-9 ) 3 ) S16668-5 ) 2 ) S13490-93 ) 27/35 1 ) S13490-83 ) 50/25V 2 ) S13490-42 ) ) 150pF/100 .022/50 1.0/35 C17 ) 1 ) S13490-39 C20 ) 1 ) S13490-130 2 ) S14293-18 ) DPST RELAY 4 ) T12705-44 ) DIODE 1000V/1A ) CR1,CR2 ) D1,D2,D8,D9 D3,D4,D5,D6,D7,D15,D16,D18 B209 B208 POWER PART NO. REQ'D ITEM C1,C4,C9,C12 ) 18/15 ) .27/50 ) 13 ) 9 ) T12702-29 ) 1N4744A 4 ) T12702-40 ) 1N4735 3 ) T12702-19 ) 1N4742A 1 ) S20351-6 ) HEADER 3 ) S15000-22 ) OPTO ISOLATOR 1 ) T12704-75 ) FET (SS) 4 ) T12704-73 ) 4 ) S24376-2 ) T12199-1 ) 1N4004 D20,D21,D22,D23,D24 DZ1,DZ3,DZ5,DZ6,DZ8,DZ10 DZ12,DZ13,DZ14 ) DZ2,DZ4,DZ9,DZ11 ) DZ7,DZ15,DZ16 C1 1A ) J10 ) OCI1,OCI3,OCI4 ) Q1 ) Q2,Q3,Q4,Q5 R3 DZ1 ) R1,R2,R3,R4 ) R5,R6,R7,R8,R15,R16,R17 40/10W B203 ) R9,R10,R11,R12,R13,R14,R19 DZ2 C2 R5 R9 R6 R7 R10 R11 R8 S19400-1001 ) 1K 1/4W 20 ) S19400-10R0 ) 10 1/4W ) S19400-1503 ) 150K 1/4W S19400-1000 ) 100 1/4W ) 221K 1/4W R57,R64,R65,R66,R67,R97 R13 R12 ) R18,R33,R37,R54,R55,R56 R1 DZ3 IC PKG MOSFET (SS) 19 R20,R21,R22,R58,R59,R60 R61,R62,R63,R68,R69,R70 1RC R2 R4 R71 ) R23,R24,R25,R26,R34,R43 10 R51,R53,R98,R107 ) R27 1 R14 DZ4 C3 DZ6 R22 R15 R21 R16 R20 R17 R19 R18 DZ5 R28,R36,R38,R44,R47,R87 ) ) 10 ) S19400-2213 ) 12 ) T14648-19 R88,R96,R118,R119 R29,R30,R31,R32,R73,R74 ) 1K 5W R75,R76,R77,R78,R80,R81 B206 ) R35 ) R25 R26 S19400-1002 ) 10K 1/4W ) S19400-2432 ) 24.3K 1/4W R41 ) 1 ) S19400-5620 ) 562 1/4W R42 ) 1 ) S19400-2801 ) 2.8K 1/4W 3 ) S19400-7681 ) 7.68K 1/4W 4 ) S19400-6191 ) 6.19K 1/4W 2 ) S19400-2001 ) 2.0K 1/4W 4 ) S19400-1004 ) 1M 1/4W 3 ) S19400-2212 ) 22.1K 1/4W ) ) R50,R52,R101,R103 ) ) D2 R24 R82,R83,R84,R85 ) R89,R90,R92 Q1 B205 ) 1 ) S19400-1822 ) 18.2K 1/4W R23 R95 ) 1 ) S19400-4751 ) 4.75K R44 R99,R108 2 ) S19400-3323 ) 332K 1/4W 1 ) S19400-1652 ) 16.5K 1/4W 2 ) S19400-1502 ) 15K 1/4W R46 R97 R84 D20 D15 R88 OCI3 R80 R81 R32 R93 R40 R47 R87 ) ) ) R102,R110 C13 R29 R30 R31 C21 R104 ) 1 ) S19400-1372 ) 13.7K 1/4W R105 ) 1 ) S19400-1821 ) 1.82K 1/4W R106 ) 1 ) S19400-2941 ) 2.94K 1/4W R111 ) 1 ) T12300-79 2 ) S19400-2211 ) 2.21K 1/4W ) 47.5K 1/4W ) R112,R113 01J C18 R96 D8 R91 D16 C17 X1 C8 R45 R83 D5 R34 C5 R28 C7 B201 X2 T10812-41 2 ) S19400-3321 1 ) S13000-46 2 ) S15128-4 1 ) S15128-10 ) ) ) ) ) 10K 1/2W TRIMMER ) ) ) 3.32K 1/4W TRANSFORMER IC,LM224,OP-AMP ) IC,431,VOLTAGE REF. C15 Q3 R38 CAPACITORS = MFD/VOLTS RESISTORS = OHMS R39 C6 X3 C19 1T D21 D24 R90 R114 R110 R111 R116 Q2 Q5 Q4 R53 R119 R117 DZ12 R103 D22 DZ11 DZ13 ) R109 C20 R115 C11 R71 R64 R70 R65 R69 R66 R68 R67 B202 R63 R102 R100 DZ14 R79 R107 R108 R101 R54 R58 R55 R59 R56 R60 R57 R61 C10 R72 1 D23 R51 R106 ) R37 D3 D7 R99 R115 1 WATT 1 OHM 1% RESISTOR D18 R49 R105 R62 DZ9 R94 B207 R104 S19400-4752 ) C16 R48 DZ10 R85 R92 R98 R42 DZ8 R95 D4 D6 R41 ) X2 R82 R33 1 X1,X3 OCI4 OCI1 C9 3A ) T1 R50 R43 R114 R116,R117 R93 R52 31.6K 1/4W ) 1 R100 R89 ) 5 R72,R79 DZ15 S19400-3162 ) R45,R48,R94 2RC DZ7 C4 R27 ) R40 R39,R46,R49,R91,R109 2A 1 R118 R73 C12 R78 4A R112 R36 R113 DZ16 C14 D9 B204 R35 R75 R74 R77 R76 0 3-19-99 0 NOTE: 12.00 ~.04 G 3440-1B 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 J33 4 2 AUX 6 4 AC POWER 3 1 J30 BOARD 10 6 1 J34 8 4 3000V CHASSIS SOLENOID, TO: TORCH, J31 2 3000V NOZZLE 10 5 6 3 2 8 1 4 J32 6 TO: CONTROL BOARD J30 15J 14 7 CR1 6 5 -2V GND HP2201 OCI1 Vcc 8 +15V AUX 35V 1000 D5 D3 +17V SUPPLY +17V C18 D4 D2 CHASSIS OCI2 CNY17-3 2 1 50V 8 50V 820p C12 POWER COM D10 J32 TP5 J30 J30 8 CIRCUIT (AIR) 6 400V .1 C33 15W 1.5K R53 15W 1.5K R51 15W 1.5K R66 A 5 A1 T12705-56 C 8 WORK +t 60V 7 R64 A 7 A1 T12705-56 C B12 4 5 AUX 1W 12V DZ8 C20 C23 LED2 2 J31 6 9 1 10 J32 J32 12 11 7 6 4 J34 J34 J32 J32 J30 5 J32 J32 J32 J32 J32 3000V .0047 C27 100V 1A Q3 3 J34 4 J34 5 9 G E LED3 C 15W 56 C15 2000V D12 N.A. 1W D25 TO +t 1% 13W +t R15 600V .05 C31 60V .13 TRIGGER 1400V .0047 60V .13 REMOTE 25 5W R5 PILOT C9 DZ1 DZ2 1W 15V 5 1 J31 J31 5 6 J34 J34 R19 0.001 EACH 1000V C25 C7 C6 C5 1W G 15V R14 A 15V .1 LED6 6 E C A2 4 TRIGGER SOLENOID AIR R18 0.001 A A2 C 5 C A2 7 B2 C1 Labeled X40 on board (26:26) +15V 24VAC XFMR 1% 13W +15V 2 1 3 D9 D16 NOZZLE 3 2 1W D17 50V 50 C13 COM HP2201 28mA 5.6mH L1 +t 2 NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE D7 D6 50V 0.1 C28 AUX +17V COM D1 J32 AUX D11 D8 6 D23 +17V 5 4 8.25K R57 1400V .0047 C21 +32V 1A, 400V R30 4.75K D21 5W 15V DZ3 1W 12V DZ12 Q5 1.21K 50V 820p C8 LED5 UNLESS OTHERWISE SPECIFIED) D13 Q4 4A 100V 7 8 J34 CR1 2 1 OCI4 6 3 2 1 5 4 B21 8 7 TO CONTROL BOARD TRIGGER SIGNAL 3 J31 J31 CONTROL BOARD SIGNAL TO TRANSFER SHUNT CONTROL BOARD SIGNAL TO ELECTRODE SHUNT X1 4 J31 12 VOLTAGE NET 8 1 LED-6 X- L 10918 3-19-99 EARTH GROUND CONNECTION FRAME CONNECTION COMMON CONNECTION POWER SUPPLY SOURCE POINT SUPPLY 4 5 DZOCI- TP38 31 66 CD- R- Q- = TRIGGER OFF LAST NO. USED OPEN SHORTED = TRIGGER ON C38 J32 600V .05 C32 60V .13 +t R17 +t 60V .13 R16 4 2 14 1 3 GND INV IN N.I. IN Vin + Vc OUT SIGNAL OK TO MOVE REMOTE ELECTRODE LABELS COM 4 5 D26 1400V .0047 C10 J33 J33 COM J32 J33 J33 C22 +15V CNY17-3 +17V S D 1N4936 D22 50V .0047 C19 -2V 35V 27 C16 9 J34 PILOT DRIVE 100V PILOT R29 G 13 Q8 1A 11 UNLESS OTHERWISE SPECIFIED) AUX 2N4401 LED4 CIRCUIT 100V 1A Q1 16 +15V - 1 CR1 + PILOT D31 (UNLESS OTHERWISE SPECIFIED) 1/4W MFD ( .022/50V 80 AMP PLASMA CUTTER DIODES = RESISTORS = Ohms ( CAPACITORS = ELECTRICAL SYMBOLS PER E1537 GENERAL INFORMATION C29 R20 2 D20 2.00K TRIGGER AUX 1W 7 -2V R35 10W 100 100V 1A Q7 1.21K R62 D19 50V 100 DZ7 12V 1 C14 C24 HP2201 OCI1 LED1 FILE NAME: L10918_1A1 +17V 50V 820p C17 OCI3 CNY17-3 2 1 12V DZ11 D15 OCI1 D14 +32V 3A 600V D18 D24 3A 600V 1.00K PILOT DRIVE CIRCUIT (ELECTRODE) 60V .13 20J 75V TP4 15W 2.5K 15W 2.5K J31 (NOZZLE) SOLENOID ENABLE R33 13 J32 4 J30 1 J30 WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY J31 J31 ON = ENABLE BOARD CONTROL ENABLE FROM SOLENOID ON = ENABLE BOARD CONTROL ENABLE FROM PILOT AUX 1000V 3A D29 2000V EACH .0015 S1 PILOT WINDINGS B1 DZ10 1W 15V DZ9 PILOT 332 SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE NOTES : S Q2 4A 100V 1N4936 D 3A D30 1000V C11 PILOT DRIVE FEEDBACK VOLTAGE REMOTE 35V C2 1.0 G 1000V 3A D27 C35 2000V EACH .0015 R55 Labeled X20 on board R38 EACH .0015 1200V 45A Q6 ISOLATION BETWEEN CIRCUITS ( MINIMUM 0.20'' ) 180J TP1 480V 15W 80 R63 CHASSIS ELECTRODE 3000V .0047 C26 15W 1.5K R52 15W 1.5K R50 15W 1.5K R65 A1 A 3 A1 3000V 480V 180J 4 T12705-56 C A 1 SOLENOID ENABLE 180J TP2 480V C T12705-56 C37 TP3 .0047 .0047 .0047 3000V C36 C30 .0047 15W 56 C3 R3 C4 TO: AMPHENOL 5 1 12VAC XFMR 3A 1000V ON = ENABLE BOARD CONTROL C34 R31 R1 2000V B11 R8 R21 EACH .0015 R6 R59 Labeled X2 on board 511 Labeled X4 on board 1.50K R4 R11 R36 D28 ENABLE FROM SOLENOID J31 CHASSIS TO: CONTROL 3 1 +15V 511 R2 15W 200 1.00K 15W 200 511 R25 R23 10W 160 (14:13) 511 5.11K S2 MAIN WINDING 221K 3.92K R13 R12 R10 1.50K 475 R22 (WORK) 1.21K 1.21K R60 R7 P4 R32 3.32K R26 221K 3.74K R58 P3 332 R34 R24 3.74K 1.50K 475 3.92K R27 1.50K R54 1.21K R61 R28 2.00K R56 P2 825 P1 R9 MAIN 221K (ELECTRODE) CHOKE TRANSFORMER ELEC L- 1 CR- 1 SOLENOID ELECTRICAL DIAGRAMS G-8 SCHEMATIC - OUTPUT PC BOARD NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. PRO-CUT 80 G-9 ELECTRICAL DIAGRAMS PC BOARD ASSEMBLY - OUTPUT BOARD REQ'D ITEM ) C1,C3,C11,C15,C34,C35 ) C2 1 ) C4,C26,C27,C30,C36,C37 ) C5,C6,C7,C25 3 ) 1 ) ) ) 1 C16 ) 1 C18 ) 1 ) C20,C22,C23,C24,C29,C38 ) C28 G3439-1 D24 R3 DZ11 D13 R60 D21 D20 C14 C13 R35 C32 C31 R53 R51 R66 D12,D22 ) D18,D24 ) D12 R58 R24 R11 D22 LED5 R15 D26 C10 R17 R23 D19 D25 R19 R28 ) R38 R10 D4 C27 D5 D2 D3 D14 TP4 TP5 D1 R56 R9 C8 C4 C38 C37 R1 D30 C11 B1 X20 C36 B2 X40 C1 D29 J31 J34 J32 ) .022/50 ) .1/50 .05/600V 0.1/400 ) S13929-10 ) J30 ) T12705-34 ) T12705-46 RELAY,DPDT,24VDC ) 1N4936 ) T12705-50 DIODE ) 1000V/3AMP DIODE ) T12702-29 1N4744A 1 ) T12702-23 ) 1N5352B 4 ) T12702-19 ) 1N4742A ) 1 ) S20351-6 J31 ) 1 ) S20351-10 ) 1 ) S20351-14 HEADER ) RT. ANGLE HEADER ) HEADER J33 ) 1 ) S20351-4 ) HEADER J34 ) 1 ) S20351-8 ) HEADER L1 ) ) ) OCI1 ) Q1,Q3,Q7,Q8 ) Q5 ) Q6 ) 5.6mH ) T13657-2 ) RED LED ) T13657-3 ) GREEN LED ) ) 3 S15000-26 ) S15000-10 ) T12704-73 ) IC PKG MOSFET (SS) ) 2 ) T12704-80 ) HEXFET TRANS. (SS) 1 ) T12704-86 ) TRANSISTOR,IGBT,1200V,45A ) 2 ) T12300-47 ) 15 W 200 OHM RESISTOR ) 1 1 ) 2 ) ) S19400-5110 ) T14648-2 3 ) ) ) ) ) ) 25 5W ) S19400-2213 ) S19400-1211 ) 1.21K 1/4W ) S19400-3921 ) 3.92K 1/4W ) 2.0K 1/4W S18380-3 ) 2 ) S23995-1 ) 2 ) ) S19400-2001 ) 2 5 1 1 ) 221K 1/4W 5 ) R30 1.5K 1/4W 2 ) ) 15W / 56 OHM PWR RESISTOR ) S19400-1501 R18,R19 ) 511 1/4W ) ) R20,R54 R14,R15,R16,R17,R33 2N4401 T12300-66 4 ) R9,R13,R27 ) T12704-68 ) 1 R6,R8,R28,R58 R21 OPTO ISOLATOR ) ) R22 OPTOCOUPLER,LOGIC-OUT 4 ) R2 R3,R4 ) T12218-2 2 4 1 OCI2,OCI3,OCI4 R5 ) 1 ) R23,R25 J33 S16668-11 J32 R10,R11,R24,R29,R62 C30 D10 TP3 C26 L1 D11 OCI4 S16668-5 ) ) 4 ) R12,R26 C28 R33 OCI3 R64 TP1 D7 R36 TP2 D15 LED2 OCI2 CR1 DZ1 C29 R26 R32 C17 C24 R27 R31 C20 R12 C21 2A DZ2 D17 LED4 C2 DZ10 R20 R54 DZ7 DZ8 R6 R8 C12 Q6 R22 C18 D16 R13 D8 R57 D6 R7 D31 ) ) 4 ) R1,R38 Q5 DZ9 R52 R50 R65 LED1 Q1 R14 R62 R63 R55 R2 R16 C33 C25 C7 C6 C5 LED6 Q3 .0047 or .005/1400 S13490-93 ) 2 DZ7,DZ8,DZ11,DZ12 Q2,Q4 D23 R5 C9 S13490-121 ) 2 ) LED1,LED2 R18 ) T11577-57 1 LED3,LED4,LED5,LED6 LED3 B21 S13490-71 ) ) J30 OCI1 Q4 ) T11577-52 S13490-72 ) ) CR1 1.0/35 .0047/3000V T11577-46 1 DZ1,DZ2,DZ9,DZ10 R30 Q2 820pF/50 ) ) DZ3 D9 .1/1000 ) S16668-7 2 C33 D27,D28,D29,D30 R59 C23 C22 C19 R21 R25 C3 C34 R34 X2 6 ) D26,D31 DZ3 DZ12 1A ) D17,D19,D20,D21,D23,D25 Q8 R61 ) S20500-1 D10,D11,D13,D14,D15,D16 C16 Q7 X1 D28 C35 C15 D27 OUTPUT D18 B11 R29 R4 S13490-42 T11577-58 ) 1 ) C31,C32 .0015/2000V ) ) ) ) ) 3 C14 IDENTIFICATION PART NO S20500-5 ) C13 C9,C10,C21 B12 6 4 ) C8,C12,C17 X4 ) 6 ) T14649-11 ) T14650-4 ) ) 160/10W ) S19400-3321 ) 1 THERMISTOR,PTC,0.08-0.19 OHMS,1.85A SHUNT RESISTOR,.001 OHM,4W ) 3.32K 1/4W 15W.,2500 OHM RESISTOR ) S19400-4751 4.75K R31,R32 ) 2 ) S19400-4750 ) 475 1/4W R34,R61 ) 2 ) S19400-3741 ) 3.74K 1/4W ) T14650-1 ) R35 1 R50,R51,R52,R53,R65,R66 ) R55,R60 ) ) 6 ) 2 ) T14649-4 100 10W ) 1500 OHMS, 15 W. RESISTOR ) S19400-1001 1K 1/4W R56 ) 1 ) S19400-8250 ) 825 1/4W R57 ) 1 ) S19400-8251 ) 8.25K 1/4W ) R59 ) 1 ) S19400-5111 5.11K 1/4W R63 ) 1 ) T14650-2 ) 80 15W R64 ) 1 ) S18380-9 ) THERMISTOR,PTC,10 OHMS,400MA ) TP1,TP2,TP3 3 ) ) 1 ) T13640-9 ) 1 ) T13640-15 1 ) S15018-19 X1 ) ) 480V/180J MOV ) 15J T13640-20 TP4 TP5 ) ) 20J IC,DRIVER,FET,6A CAPACITORS = MFD/VOLTS RESISTORS = OHMS 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 ELECTRICAL DIAGRAMS SCHEMATIC - DISPLAY PC BOARD 1 2 R2 2700p 50V 8 3 6 4 4 LED8 +15V 5 5 3 +15V 6 R17 C1 2 HLMP-2855 2N4401 R1 14 7 1 COM 7 825 R4 HLMP-2550 100 R3 6.81K SIGNAL Q1 3.32K J40 "READY" 100 LED9 5 8 8 100 100 R7 R8 6 C2 R6 2700p 50V 4 3 8 2 R18 2 2.67K HLMP-2655 5 HLMP-2350 13 1W 7 1 2N4401 R5 POT 10K 10V 7 6.81K SIGNAL 3.32K J40 "AIR LOW" Q2 +15V LED6 CONTROL J40 DZ1 J40 J40 COM 1 7 6 4 AIR SET J40 LED7 +15V 2 2.67K 1 1 100 R12 2 2N4401 R9 9 2 3 6 R10 50V 4 5 +15V 5 3 4 12 LED4 6.81K 2700p J40 8 4 C3 RESET J40 J40 HLMP-2450 SIGNAL 3.32K J40 "THERMAL" R11 Q3 3 11 HLMP-2755 100 J40 7 1 R19 5 3 COM 6 7 LED5 COM 8 +15V 8 LED3 7 6 R14 C4 2700p 50V 2 3 4 8 3 6 2 LED2 2 3 COM 4 LED1 1 5 J40 HLMP-2400 HLMP-2655 75.0 5 4 6.81K SIGNAL 75.0 2N4401 R13 8 7 1 R16 HLMP-2350 3.32K J40 "SAFETY" R15 Q4 J40 FILENAME: M18920_1AA R20 NOTES : N.A. CAPACITORS = MFD ( .022/50V DIODES = 1A, 400V 1/4W 11 10 9 C5 4.7 7 8 6 5 4 3 2 1 LAST NO. USED UNLESS OTHERWISE SPECIFIED) UNLESS OTHERWISE SPECIFIED) (UNLESS OTHERWISE SPECIFIED) SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE NUMBER. J40 12 ELECTRICAL SYMBOLS PER E1537 NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE 15 13 GENERAL INFORMATION WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY J40 14 243 1 RESISTORS = Ohms ( +15V 15 6 R- 20 DZ- 1 C- 5 LED- 9 LABELS SUPPLY VOLTAGE NET POWER SUPPLY SOURCE POINT COMMON CONNECTION FRAME CONNECTION EARTH GROUND CONNECTION 35V 10 COM 10-31-97D M18920 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. PRO-CUT 80 G-11 ELECTRICAL DIAGRAMS QTY. PART No. IDENTIFICATION C1,C2,C3,C4 4 S16668-4 2700pF/50 C5 1 S13490-25 4.7/35 DZ1 1 T12702-27 1N4740 LED1 1 M18875-1 LIGHT BAR,LED,YELLOW LED2,LED7 2 M18875-5 LIGHT BAR,LED,RED LED3,LED6 2 M18875-2 LIGHT BAR,LED,RED LED4 1 M18875-6 LIGHT BAR,LED,YELLOW LED5 1 M18875-3 LIGHT BAR,LED,YELLOW LED8 1 M18875-7 LIGHT BAR,LED,GREEN LED9 1 M18875-4 LIGHT BAR,LED,GREEN Q1,Q2,Q3,Q4 4 T12704-68 2N4401 R1,R5,R9,R13 4 S19400-3321 3.32K 1/4W R2,R6,R10,R14 4 S19400-6811 6.81K 1/4W R3,R4,R7,R8,R11,R12 6 S19400-1000 100 1/4W R15,R16 2 S19400-75R0 75 1/4W R17 1 S19400-8250 825 1/4W R18,R19 2 S19400-2671 2.67K 1/4W R20 1 S19400-2430 243 1/4W 1-9-98M ITEM L 10721-1 PC BOARD ASSEMBLY - DISPLAY BOARD 4.00 1.10 1.65~.04 LED5 LED3 R16 R17 R19 LED2 C5 R13 C4 DZ1 R9 Q3 R11 R10 Q2 C3 R14 R5 R7 R6 C2 R1 R2 R20 LED1 R8 Q1 LED4 R18 LED7 R15 LED8 R12 Q4 C1 R3 1.00 LED6 LED9 R4 DISPLAY 1.40 04J L10721-1 0 0 NOTE: .20 4.30 4.50~.04 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: ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ SD287 01/99