Download Viper Service Manual - Red-D

SVM140-A
November, 1998
™
PRO-CUT 55
For use with machine code numbers 10473, 10474
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
Premier Manufacturer of Industrial Motors
• 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 V-belts, 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 55
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 55
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 55
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 55
v
v
MASTER TABLE OF CONTENTS FOR ALL SECTIONS
Page
Safety.................................................................................................................................................i-iv
Installation .............................................................................................................................Section A
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
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 ....................................................................................................P309 Series & P210-K
PRO-CUT 55
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 55
A-2
A-2
INSTALLATION
TECHNICAL SPECIFICATIONS - PRO-CUT 55
INPUT RATINGS
Single Phase Input
Voltage and Hertz
Input Currents
Rated Output Amps
208/1/60
230/1/60
460/1/60
60
55
30
55
55
55
208/1/60
230/1/60
460/1/60
44
40
23
40
40
40
Three Phase Input
Voltage and Hertz
Input Currents
Rated Output Amps
208/3/60
230/3/60
460/3/60
31
28
17
55
55
55
208/3/60
230/3/60
460/3/60
23
21
15
40
40
40
IDLE CURRENT AND WATTS
230/1/60
0.42 Amps
98 Watts
RATED OUTPUT
Duty Cycle
Rated Output Amps
50%
100%
55
40
OUTPUT
Current Range
Open Circuit Voltage
Pilot Current
25 - 55 Amps
335VDC Maximum
18 Amps @ 100%
Duty Cycle
PRO-CUT 55
A-3
A-3
INSTALLATION
TECHNICAL SPECIFICATIONS (Cont’d) - PRO-CUT 55
GAS REQUIREMENTS
Required Gas Flow Rate
Required Gas Inlet Pressure
70 PSI @ 360 SCHF
(4.8 Bar. @ 10160 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
70 Amps
40 Amps
2 Input Supply Wires
#8 (8.4mm2)
#8 (8.4mm2)
1 Ground Wire
#10 (5.3mm2)
#10 (.3mm2)
230VAC Single Phase
460VAC Single Phase
40 Amps
20 Amps
#10 (5.3mm2)
#10 (5.3mm2)
#10 (5.3mm2)
#10 (5.3mm2)
PHYSICAL DIMENSIONS
Height
Width
Depth
Weight with
Torch Cable
12.6 Inches
320 mm
11.0 Inches
280 mm
26.0 Inches
660 mm
70 lbs. (32 kg.)
(25 ft. cable)
85 lbs. (39 kg.)
(50 ft. cable)
PRO-CUT 55
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 55 grounding terminal (located
on the side of the Case Back Assembly) to a good
electrical earth ground.
• Always wear dry, insulating gloves.
• Turn the 55 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 55 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 55. 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 55 cannot be stacked.
• Either the front or rear handles or both may be used
to lift or move the machine.
TILTING
The Pro-Cut 55 must be placed on a stable, level surface so it will not topple over.
HIGH FREQUENCY INTERFERENCE
PROTECTION
The Pro-Cut 55 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 ProCut or possibly even damage the control system or
power supply components.
A-5
INSTALLATION
INPUT CONNECTIONS
WARNING
ELECTRIC SHOCK can kill.
• Have a qualified electrician install and
service this equipment.
• Turn the input power off at the fuse box
before working on this equipment.
A-5
GROUND CONNECTION
The frame of the Pro-Cut 55 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
machine’s voltage, phase, and frequency as specified
on the machine’s rating plate. See Figure A.1.
FIGURE A.1 – RATING PLATE LOCATION
INPUT POWER CORD CONNECTOR
INSTALLATION
The Pro-Cut 55 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
2
3
1. CASE BACK
2. RATING PLATE
3. POWER CORD CONNECTOR WITH STRAIN RELIEF
The Pro-Cut 55 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.
Fuse the input circuit with the super lag fuses or delay
type circuit breakers recommended on the Technical
Specifications page. Choose an input and grounding
wire size according to local or national codes; also see
the Technical Specifications page. Using fuses or
circuit breakers smaller than recommended may result
in “nuisance” shut-offs from inrush currents, even if
you are not cutting at high currents.
A-6
A-6
INSTALLATION
RECONNECT PROCEDURE
When received directly from the factory, the machines
are internally connected for 230 VAC. Reconnection
will be necessary if a higher input voltage is used. To
reconnect the Pro-Cut to 460 VAC or to connect back
to 230 VAC, follow the directions as outlined below.
Follow this procedure ONLY while the Pro-Cut is disconnected from the input power.
CAUTION
Failure to follow these instructions can cause immediate failure of components in the welder.
FIGURE A.2 – RECONNECTION DIAGRAM
RECONNECT PROCEDURE
WARNING
• Disconnect input power before
inspecting or servicing machine.
• Do not operate with wraparound
removed.
ELECTRIC
SHOCK
CAN KILL
• Do not touch electrically live parts.
• Only qualified persons should install,
use, or service this equipment.
1. BE SURE POWER SWITCH IS OFF.
2. CONNECT LEAD 'A' TO DESIRED INPUT VOLTAGE RANGE.
440 - 460V
1. Open the access door on the side of the machine.
Connection instructions are also included on the
inside of the door.
380 - 415V
220 - 230V
'A'
200 - 208V
2. For 230: Position the large switch to 200-230. See
Figure A.2.
For 460: Position the large switch to 380-460. See
Figure A-2.
3. POSITION SWITCH TO DESIRED INPUT VOLTAGE RANGE.
VOLTAGE = 380 - 460V
3. Move the “A” lead to the appropriate terminal.
VOLTAGE = 200 - 230V
A-7
A-7
INSTALLATION
GAS INPUT CONNECTIONS
FIGURE A.3 - COMPRESSED GAS CONNECTION
Supply the Pro-Cut 55 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 55 can
cause severe problems. Use only a clean air
supply.
2
• Connect the gas supply to the Pro-Cut 55’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 Pro-Cut
55 regulator should never exceed 150 psi.
• Install a hose between the nitrogen gas cylinder regulator and the Pro-Cut 55 gas inlet.
PRO-CUT 55
A-8
A-8
INSTALLATION
OUTPUT CONNECTIONS
FIGURE A.4 - TORCH CONNECTION
AT CASE FRONT
TORCH CONNECTION
The Pro-Cut 55 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.
XXXX
All torches are connected to the Pro-Cut with a quick
connect at the case front for easy change over. See
Figure A-4.
For more information on the torch and its components,
refer to the PCT 80 Operator’s Manual (IM588).
XXXX
XXXX
XXXX
PRO-CUT 55
OFF
1
1. TORCH CONNECTION
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
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
PRO-CUT 55
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 55
B-2
B-3
OPERATION
GENERAL DESCRIPTION
The Pro-Cut 55 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 55 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 55 comes standard with an air regulator,
coarse air filter, and pressure gauge. The machine also
comes with an 11 foot (3.35m) input power cord. There
are four different torch and cable systems to choose
from: hand-held torch with 25 foot (7.62m) or 50 foot
(15.24m) cable, machine and robotic torch both with
25 foot (7.62m) and 50 foot (15.24m) cable.
Consumables are included with each Pro-Cut purchase so that cutting can begin right out of the box.
Consumables can also be ordered as individual packages. An undercarriage kit can be ordered separately.
The Pro-Cut 55 initiates the plasma arc with a simple,
yet reliable, touch-start mechanism. This system eliminates many of the failure problems associated with hifrequency start systems. The Pro-Cut 55 is capable of
cutting with nitrogen or air.
The Pro-Cut 55 is controlled by a microprocessorbased control board. The machine performs rudimentary self troubleshooting when powered up, which aids
in field servicing.
B-3
DESIGN FEATURES AND
ADVANTAGES
The microprocessor controlled Pro-Cut 55 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, 25 - 55 amps.
• Reliable touch start mechanism for plasma arc initiation.
• Unique microprocessor controlled starting
sequence for safe and consistent starting.
• Rapid arc transfer for fast cutting of expanded
metal.
• High transfer distance for ease of use.
• Input overvoltage protection.
• 3.0 second pilot arc.
• Purge momentary push button.
• Air regulator and pressure gauge located on the
front of machine for convenience.
• ”Parts-in-Place” mechanism to detect proper installation of consumables and torch.
• Automatic detection of faulty output control.
• In-line coarse air filter.
• Preflow/Postflow timing. Preflow is eliminated if arc
is re-initiated in Postflow.
• Thermostatic Protection.
• Solid state overcurrent protection.
RECOMMENDED PROCESSES AND
EQUIPMENT
• Works with pure nitrogen for cutting nonferrous
materials.
The Pro-Cut 55 is capable of all cutting and gouging
applications within its output capacity of 25 to 55
amps. These applications include thin gage sheet
metal and expanded metal.
• Reconnectable for 230 VAC or 460 VAC inputs.
• Quick disconnect torch.
• Display indicators for machine status.
• Unique electrode and Vortech™ nozzle design for
optimum cooling and long life.
OPERATIONAL FEATURES AND
CONTROLS
The Pro-Cut 55 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 Vortech™ nozzle for better starting reliability and higher quality cuts.
• Unique drag cup design for durability and elimination of double arcing.
B-4
B-4
OPERATION
CUTTING CAPABILITY
The Pro-Cut 55 is rated at 55 amps, at 50% duty cycle
on a 10 minute basis or 40 amps, at 100% duty cycle.
If the duty cycle is exceeded, a thermal protector will
shut off the output of the machine until it cools to the
normal operating temperature.
Figure B.1 shows the cut capacity of the Pro-Cut 55
when cutting mild steel. The graph plots cut thickness
vs. torch travel speed with a torch standoff of 0.15 in.
(3.8mm).
Example: 0.25 material
Amps
Speed (IPM)
35
45
55
38
57
62
FIGURE B.1 – LINCOLN’S PRO-CUT 55 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
35 A
0.250
0.375
0.500
Material Thickness
45 A
0.625
55 A
0.750
CONSUMABLE LIFE
LIMITATIONS
The expected life for the Pro-Cut 55's electrode under
normal operating conditions is approximately 320
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 55 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 55 system.
B-5
OPERATION
B-5
CONTROLS AND SETTINGS
PILOT ARC CONSIDERATIONS
FIGURE B.2 - CASE FRONT CONTROLS
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. 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.
9
8
7
6
XXXX
XXXX
XXXX
XXXX
5
1
PRO-CUT 55
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.
OFF
2
4
3
1.
2.
3.
4.
5.
6.
7.
8.
9.
OUTPUT CURRENT CONTROL KNOB
TORCH CONNECTOR
WORK CABLE
INPUT POWER SWITCH
GAS REGULATOR KNOB
GAS REGULATOR GAUGE
GAS PURGE BUTTON
RESET BUTTON
STATUS (DISPLAY) BOARD INDICATORS
CUTTING OPERATION
When preparing to cut or gouge, position the machine
as close to the work as possible. Make sure you have
all materials needed to complete the job and have
taken all safety precautions. It is important to follow
these operating steps each time you use the machine.
1. OUTPUT CURRENT CONTROL KNOB - Adjusts
the amount of cutting current applied. Affects cutting speed, dross formation, cut width, heat zone
and travel speed.
2. TORCH CONNECTOR - Quick-connect type coupling for the PCT 80 cutting torch.
3. WORK CABLE - Provides clamp and cable connection to workpiece.
4. ON/OFF POWER SWITCH - Turns machine on or off.
5. 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.
6. GAS REGULATOR GAUGE - Provides gas pressure
reading as set by the gas regulator knob.
7. 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.
8. RESET BUTTON - Used to reset the machine following a safety circuit trip.
9. STATUS (DISPLAY) BOARD INDICATORS - Four
lights indicating Power, Gas Low, Thermal and
Safety.
• 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.
PRO-CUT 55
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
5° - 15°
Leading Angle
Direction of Travel
10° - 20° 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 3/16”
(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.
• Use the drag cup with a metal template to prevent
nozzle double arcing.
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.
B-7
B-7
OPERATION
WARNING
ELECTRIC SHOCK can kill.
• Turn off machine at the disconnect
switch on the front of the machine
before tightening, cleaning or replacing consumables.
- Check the conditions of the inside of the nozzle. If
debris has collected, rub the electrode on the
inside bottom of the nozzle to remove any oxide
layer that may have built up. Refer to
“Suggestions for Extra Utility from the Pro-Cut
System.”
- Check the condition of the electrode. If the end has
a crater-like appearance, replace it along with the
nozzle. The maximum wear depth of the electrode
is approximately .062 in. (1.6mm). A green and
erratic arc will indicate definite electrode failure.
The electrode should be replaced immediately.
• Replace the nozzle when the orifice exit is eroded
away or oval shaped.
• After the problem is found, or if there is nothing
apparently wrong, reset the machine by pressing
the "Reset" button. (It is possible for electrical noise
to trip the safety circuit on rare occasions. This
should not be a regular occurrence.)
• If the machine does not reset or continues to trip,
consult the Troubleshooting Section.
• Use the proper cutting or gouging procedures
referred to in “Procedure Recommendations”
below.
PREHEAT TEMPERATURE FOR
PLASMA CUTTING
Preheat temperature control is not necessary in most
applications when plasma arc cutting or gouging.
Preheat temperature control may be necessary on
high carbon alloy steels and heat treated aluminum for
crack resistance and hardness control. Job conditions, prevailing codes, alloy level, and other considerations may also require preheat temperature control.
The recommended minimum preheat temperature for
plate thickness up to 1/2 in. (12.7mm) is 70°F (21.1°C).
Higher temperatures may be used as required by the
job conditions and/or prevailing codes. If cracking or
excessive hardness occurs on the cut face, higher preheat temperature may be required.
PROCEDURE RECOMMENDATIONS
When properly used, plasma arc cutting or gouging is
a very economical process. Improper use will result in
a very high operating cost.
GENERAL - IN ALL CASES
• Follow safety precautions as printed throughout this
manual and on the machine.
THIN GAUGE SHEET METAL
Torch Standoff
Machine Output Setting
DRAG thru 1/16"
Standoff
OutputSetting
Setting
Output
Min.thru
thruMid.
Mid-Range
Min.
Range
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.
Output set below mid-range.
• The nozzle may be dragged on the metal surface,
touching it lightly to the surface after piercing a hole.
Current control should be set below the mid-range.
• Do not allow cable or body to contact hot surface.
B-8
OPERATION
THICK SECTIONS OF METAL
Torch Standoff
Machine Output Setting
1/8" thru 3/16"
Standoff
Output Setting
Mid. thru Max. Range
Output set above mid-range.
• The best quality and consumable life will be
obtained by holding the torch off the surface about
3/16 in. (4.7mm). Too long an arc may compromise
cut quality and consumable life. The nozzle should
NOT be dragged on the work.
• Use of the S22151 Drag Cup will maintain the proper standoff. The only time not to use the drag cup
when the output control is set above mid-range is in
special, tight corners. Always hold at least a 1/8 in.
(3.2mm) standoff in those situations.
• If piercing is required, slowly lower the torch at an
angle of about 30° to blow the dross away from the
torch tip and slowly rotate the torch to a vertical
position as the arc becomes deeper. This process
will blow a lot of molten metal and dross. Be careful! Blow the dross away from the torch, the operator and any flammable objects.
• Where possible, start the cut from the edge of the
workpiece.
• Keep moving! A steady speed is necessary. Do not
pause.
• Do not allow the torch cable or body to contact a
hot surface.
SUGGESTIONS FOR EXTRA UTILITY
FROM THE PRO-CUT SYSTEM
WARNING
ELECTRIC SHOCK can kill.
• Turn off machine at the disconnect
switch on the front of the machine
before tightening, cleaning or replacing consumables.
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:
a. Never drag the nozzle on the work surface if
the output control knob is above the midrange setting.
b. Make sure the air supply to the Pro-Cut is
clean and free of oil. Use several extra in-line
filters if necessary.
c. Use the lowest output setting possible to
make a good quality cut at the desired cut
speed.
d. Minimize dross buildup on the nozzle tip by
starting the cut from the edge of the plate
when possible.
e. Pierce cutting should be done only when necessary. If piercing, angle the torch about 30°
from the plane perpendicular to the workpiece, transfer the arc, then bring the torch
perpendicular to the work and begin parallel
movement.
f. Reduce the number of pilot arc starts without
transferring to the work.
g. Reduce the pilot arc time before transferring to
the work.
h. Set air pressure to recommended setting. A
higher or lower pressure will cause turbulence
in the plasma arc, eroding the orifice of the
nozzle tip.
i. Use only Lincoln consumable parts. These
parts are patented. Using any other replacement consumables may cause damage to the
torch or reduce cut quality.
Section C-1
Section C-1
TABLE OF CONTENTS
- ACCESSORIES Accessories...........................................................................................................................Section C
Options/Accessories...................................................................................................................C-2
PRO-CUT 55
C-2
ACCESSORIES
GENERAL OPTIONS /
ACCESSORIES
The following options/accessories are available for
your Pro-Cut 55 from your local Lincoln Distributor.
K1600-1 Undercarriage - A valet style undercarriage
with pull-out handle for machine only. Provides torch
and work cable storage.
S22147-043 - Vortech™ nozzle with an .043” (1.2 mm)
Orifice
S22147-068 - Vortech™ nozzle with an .068” (1.7 mm)
Orifice
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. The shield cup does not prevent the torch tip
from touching the workpiece.
S22151 - Drag Cup - The drag cup protects the torch
by preventing the torch from touching the workpiece.
K1571 Series - PCT 80 Torches come in 25’ and 50’
lengths in either hand held or mechanized versions.
C-2
ALWAYS USE GENUINE LINCOLN ELECTRIC
ELECTRODES AND VORTECH™ NOZZLES
• Only Genuine Lincoln Electric consumables yield
the best cutting performance for the Pro-Cut 55.
• The patent pending VORTECH™ nozzle provides
an extra “kick” of swirl as the arc exits the nozzle,
which improves cutting performance. No other nozzle has this capability or can match its performance.
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
PRO-CUT 55
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.
5. Locate the two capacitor terminals (large hex head
cap screws) on the top and bottom of the Power
Board shown in Figure D.1.
• Have an electrician install and service
this equipment.
• Turn the input power off at the fuse box
before working on equipment.
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.
• Do not touch electrically hot parts.
• Prior to performing preventative maintenance, perform the following capacitor discharge procedure to
avoid electric shock.
7. Repeat the discharge procedure for the other
capacitor.
INPUT FILTER CAPACITOR
DISCHARGE PROCEDURE
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.
1. Turn off input power or disconnect input power
lines.
2. Remove the 5/16 in. hex head screws from the side
and top of the machine and remove wrap-around
machine cover.
3. Be careful not to make contact with the capacitor
terminals that are located on the top and bottom of
the Power Board on the right side of the machine.
FIGURE D.1 — LOCATION OF INPUT FILTER CAPACITOR TERMINALS
POWER
BOARD
UPPER
CAPACITOR TERMINALS
LOWER
CAPACITOR
TERMINALS
POWER
RESISTOR
RIGHT SIDE OF MACHINE
INSULATED
GLOVES
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 (Refer
to 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 55, 400-460
VAC only)
A protection circuit is included to monitor the voltage
across filter capacitors C1 and C2. In the event that
the capacitor voltage is too high, the protection circuit
will prevent output. The protection circuit may prevent
output providing all these circumstances are met:
a. Machine is connected for 400-460 VAC input.
b. Machine did not have power applied for many
months.
c. Machine will not produce output when power is
first switched on.
If these circumstances apply, the proper action is to
switch the machine on and let it idle for up to 30 minutes. This is required to condition the filter capacitors
after an extended storage time. The protection circuit
will automatically reset once the capacitor conditioning and resultant voltage levels are acceptable. It may
be necessary to turn the power switch off and back on
again after this period.
PRO-CUT 55
D-4
D-4
Maintenance
FIGURE D.2 – MAJOR COMPONENT LOCATIONS
1. Machine Base
2. Case Front
3. Output Power Board Assembly
4. Case Wraparound
5. Control Board
6. Case Back
6
7. Primary Power Board
8. Auxiliary Transformer
9. Main Transformer
4
1
5
2
3
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 55 BLOCK LOGIC DIAGRAM
WORK
NOZZLE
ELECTRODE
POWER BOARD
MAIN
TRANSFORMER
CR 1
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
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
RELAY
DRIVE
SIGNAL
IGBT
GATE
SIGNALS
ELECTRODE & TRANSFER
CURRENT FEEDBACK
SIGNAL
A
PILOT ENABLE
CONTROL BOARD
ELECTRODE SOLENOID ENABLE
D
AIR SOLENOID ENABLE
18/36VAC
THERMOSTATS
FAN
MOTORS
S
O
L
E
N
O
I
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
AUXILIARY
TRANSFORMER
PRO-CUT 55
E-2
E-2
THEORY OF OPERATION
FIGURE E.2 – INPUT LINE VOLTAGE
WORK
NOZZLE
ELECTRODE
POWER BOARD
MAIN
TRANSFORMER
CR 1
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
RELAY
DRIVE
SIGNAL
IGBT
GATE
SIGNALS
ELECTRODE & TRANSFER
CURRENT FEEDBACK
SIGNAL
A
PILOT ENABLE
CONTROL BOARD
ELECTRODE SOLENOID ENABLE
D
AIR SOLENOID ENABLE
18/36VAC
THERMOSTATS
FAN
MOTORS
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
AUXILIARY
TRANSFORMER
GENERAL DESCRIPTION
The Pro-Cut 55 is a constant current, continuous control plasma cutting power source. The inverter based
power supply design is controlled by a microprocessor
control board. The control system has a safety mechanism to insure that the nozzle and electrode are in
place before cutting or gouging. The Pro-Cut 55 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.
INPUT LINE VOLTAGE,
CONTACTOR AND MAIN
TRANSFORMER
The single-phase or three-phase input power of 200230 or 400 to 460 volts AC 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 fans, the control board
and the plasma output board.
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
E-3
E-3
THEORY OF OPERATION
FIGURE E.3 – PRECHARGE AND PROTECTION
WORK
NOZZLE
ELECTRODE
POWER BOARD
MAIN
TRANSFORMER
CR 1
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
RELAY
DRIVE
SIGNAL
IGBT
GATE
SIGNALS
ELECTRODE & TRANSFER
CURRENT FEEDBACK
SIGNAL
A
PILOT ENABLE
CONTROL BOARD
ELECTRODE SOLENOID ENABLE
D
AIR SOLENOID ENABLE
18/36VAC
THERMOSTATS
FAN
MOTORS
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
AUXILIARY
TRANSFORMER
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
input relay. 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 input relay. The
machine output will also be disabled.
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
E-4
E-4
THEORY OF OPERATION
FIGURE E.4 – MAIN TRANSFORMER
WORK
NOZZLE
ELECTRODE
POWER BOARD
MAIN
TRANSFORMER
CR 1
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
RELAY
DRIVE
SIGNAL
IGBT
GATE
SIGNALS
ELECTRODE & TRANSFER
CURRENT FEEDBACK
SIGNAL
A
PILOT ENABLE
CONTROL BOARD
ELECTRODE SOLENOID ENABLE
D
AIR SOLENOID ENABLE
18/36VAC
THERMOSTATS
FAN
MOTORS
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
AUXILIARY
TRANSFORMER
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.
E-5
E-5
THEORY OF OPERATION
FIGURE E.5 – PLASMA OUTPUT BOARD AND TORCH
WORK
NOZZLE
ELECTRODE
POWER BOARD
MAIN
TRANSFORMER
CR 1
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
RELAY
DRIVE
SIGNAL
IGBT
GATE
SIGNALS
ELECTRODE & TRANSFER
CURRENT FEEDBACK
SIGNAL
A
PILOT ENABLE
CONTROL BOARD
ELECTRODE SOLENOID ENABLE
D
AIR SOLENOID ENABLE
18/36VAC
THERMOSTATS
FAN
MOTORS
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
AUXILIARY
TRANSFORMER
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 each of the secondary windings.
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.
The output choke, which is in series with both the pilot circuit and the cutting circuit, provides current filtering to
enhance arc stability.
The PCT 80 torch uses a patented touch start mechanism
that provides superior starting performance over other
touch start systems. The torch head consists of 3 major
parts: torch body, insulator and piston. The insulator provides an electrical barrier between the piston and torch
body. The piston provides a path for electrical current to
the electrode. The piston also drives the electrode to the
nozzle for arc initiation. The torch body contains the main
torch components: the trigger, pilot arc, cutting arc, and air
flow systems are included.
A copper nozzle with a patented internal swirl is used to
focus the arc. A small, precise hole in the end of the nozzle constricts the arc and increases the current density.
As the air enters the torch head, it is directed between
the electrode and nozzle for maximum electrode cooling.
A portion of the cooling air exits the chamber through
vents in the side of the nozzle. A swirl texture located
inside the bottom of the nozzle increases the plenum air
swirl strength, and improves arc start reliability and partsin-place verification.
Plasma arc initiation occurs as follows: First, in the idle
state, a spring inside the torch head pushes the piston
and electrode forward to make continuity with the nozzle.
When the trigger is pulled, air flow begins and creates
enough back force on the electrode to overcome the
force of the spring. However, the solenoid valve allows
enough forward force on the piston to maintain continuity between the consumables. After this continuity has
been verified by the Pro-Cut’s parts-in-place circuit, output current is established and regulated. Once the current stabilizes, the solenoid valve turns off, removing the
forward force on the piston. The back pressure drives
the piston and electrode away from the nozzle, creating
the plasma arc. The air stream forces the arc out the orifice of the nozzle. This appears as a pilot arc, which can
then be transferred for cutting.
E-6
E-6
THEORY OF OPERATION
FIGURE E.6 – CONTROL AND DISPLAY BOARDS
WORK
NOZZLE
ELECTRODE
POWER BOARD
MAIN
TRANSFORMER
CR 1
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
RELAY
DRIVE
SIGNAL
IGBT
GATE
SIGNALS
ELECTRODE & TRANSFER
CURRENT FEEDBACK
SIGNAL
A
PILOT ENABLE
CONTROL BOARD
ELECTRODE SOLENOID ENABLE
D
AIR SOLENOID ENABLE
18/36VAC
THERMOSTATS
FAN
MOTORS
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
AUXILIARY
TRANSFORMER
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 ProCut 55 status and operating conditions to the user.
E-7
THEORY OF OPERATION
E-7
PROTECTION CIRCUITS
THERMAL PROTECTION
Protection circuits are designed into the Pro-Cut 55
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 55 is electrically protected from producing higher than normal output currents. If the output
current exceeds 50-60 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 fans are
operating normally, the power switch may be left on
and the reset should occur within a 15 minute period.
If the fan or fans are 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.
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 – 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
A. PASSIVE
DRAIN
B. ACTIVE
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 – TYPICAL IGBT OUTPUTS
sec
48
50
sec
sec
sec
MINIMUM OUTPUT
22 sec
22 sec
3 sec
50 sec
MAXIMUM OUTPUT
E-10
NOTES
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 55
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 216-383-2531 or 1-800-833-9353.
PRO-CUT 55
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:
PC Board can be damaged by
static electricity.
ATTENTION
Static-Sensitive
Devices
Handle only at
Static-Safe
Workstations
Reusable
Container
Do Not Destroy
• Remove your body’s static charge
before opening the static-shielding bag. Wear an anti-static wrist
strap. For safety, use a 1 Meg
ohm resistive cord connected to a
grounded part of the equipment
frame.
• If you don’t have a wrist strap,
touch an unpainted, grounded,
part of the equipment frame.
Keep touching the frame to prevent static build-up. Be sure not
to touch any electrically live parts
at the same time.
• Tools which come in contact with the PC Board must
be either conductive, anti-static or static-dissipative.
a. If the original problem does not reappear
by substituting the original board, then the
PC board was not the problem. Continue
to look for bad connections in the control
wiring harness, junction blocks, and terminal strips.
b. If the original problem is recreated by the
substitution of the original board, then the
PC board was the problem. Reinstall the
replacement PC board and test the
machine.
6. Always indicate that this procedure was followed
when warranty reports are to be submitted.
NOTE: Following this procedure and writing on the
warranty report, “INSTALLED AND SWITCHED
PC BOARDS TO VERIFY PROBLEM,” will help
avoid denial of legitimate PC board warranty
claims.
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, 216-3832531
or
1-800-833-9353
(WELD).
Machine is dead – no output – no
fan – no status indicator lights.
1. Make sure that the input power
switch is in the “ON” position.
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.
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 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
216-383-2531 or 1-800-833-9353.
PRO-CUT 55
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 55 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 55
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
216-383-2531 or 1-800-833-9353.
PRO-CUT 55
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
216-383-2531 or 1-800-833-9353.
PRO-CUT 55
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
216-383-2531 or 1-800-833-9353.
PRO-CUT 55
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 Pro-Cut
55.
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 55.
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 and the output
board. See the Wiring Diagram.
3. The output board may be faulty.
Replace.
The Safety LED is lit and ready.
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
216-383-2531 or 1-800-833-9353.
PRO-CUT 55
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 55 off. Allow
the machine to cool. The thermostat(s) will reset themselves.
Either the duty cycle has been
exceeded, the fans are not
functioning or the louvers are
blocked.
1. The 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
216-383-2531 or 1-800-833-9353.
PRO-CUT 55
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 216-383-2531 or 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 55
F-10
F-11
TROUBLESHOOTING & REPAIR
F-11
INPUT FILTER CAPACITOR DISCHARGE PROCEDURE (continued)
WARNING
ELECTRIC SHOCK can kill.
• Have an electrician install and
service this equipment.
• Turn the input power off at the
fuse box before working on
equipment.
4. Obtain a high resistance and high wattage
resistor (25-1000 ohms and 25 watts minimum). This resistor is not supplied with
machine. NEVER USE A SHORTING STRAP
FOR THIS PROCEDURE.
5. Locate the four capacitor terminals (large
hex head cap screws) shown in Figure F.1.
One pair is at the top and one pair is at the
bottom of the Power Board.
• Prior to performing preventative maintenance, perform the following capacitor discharge procedure to avoid electric shock.
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.
DISCHARGE PROCEDURE
7.
• Do not touch electrically hot parts.
1. Turn off input power and disconnect input
power lines.
2. Remove the 5/16" hex head screws from
the wraparound machine cover.
3. Be careful not to make contact with the
capacitor terminals located in the top and
bottom of the Input Power Board.
Repeat the discharge procedure for the
capacitor on the other two terminals.
8. Check the voltage across the terminals of
all capacitors with a DC voltmeter. Polarity
of the capacitor terminals is marked on the
PC board above the terminals. Voltage
should be zero. If any voltage remains,
repeat this capacitor discharge procedure.
FIGURE F.1 – LOCATION OF INPUT FILTER CAPACITOR TERMINALS
INPUT
POWER
BOARD
UPPER
CAPACITOR TERMINALS
LOWER
CAPACITOR
TERMINALS
POWER
RESISTOR
RIGHT SIDE OF MACHINE
INSULATED
GLOVES
PRO-CUT 55
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 216-383-2531 or 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 55
F-12
F-13
TROUBLESHOOTING & REPAIR
F-13
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.
FIGURE F.2 – INPUT RECTIFIER AND LEADS
#207
#207A
A
B
C
#209
PRO-CUT 55
F-14
TROUBLESHOOTING & REPAIR
F-14
INPUT RECTIFIER TEST (continued)
TABLE F.1 INPUT RECTIFIER TEST POINTS
TEST POINT TERMINALS
+ Probe
- Probe
ANALOG METER X10 RANGE
Acceptable Meter Readings
A
B
C
207
207
207
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
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 55
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.
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 216-383-2531 or 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 55
F-15
F-16
TROUBLESHOOTING & REPAIR
PRIMARY POWER BOARD RESISTANCE TEST AND
CAPACITOR VOLTAGE TEST (continued)
FIGURE F.3 – PRIMARY POWER BOARD REMOVAL
CAPACITOR (C2)
TERMINALS
+
207
202
204
PRIMARY POWER
BOARD WITH
INPUT FILTER
CAPACITORS
201
208
205
+
206
PRO-CUT POWER G3172-[ ]
F-16
203
CAPACITOR (C1)
TERMINALS
TEST PROCEDURE
1. Remove main input power to the Pro-Cut
55.
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 55
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. Reconnect leads #201, #204, #205 and #208
to their appropriate terminals.
PRO-CUT 55
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 55 connected for 400 VAC and
above, and with the appropriate input voltage
applied.
4. The following tests will be performed with
the input power applied to the Pro-Cut 55.
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
55.
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 55.
† NOTE: This test should only be conducted
with the Pro-Cut 55 reconnect switch
and “A” jumper configured for 400
VAC and above.
PRO-CUT 55
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. 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 55
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 216-383-2531 or 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 55
F-20
F-21
TROUBLESHOOTING & REPAIR
F-21
OUTPUT POWER BOARD RESISTANCE TEST (continued)
FIGURE F.4 – OUTPUT POWER BOARD LEAD LOCATIONS
X4
(B11)
B21
G3326 - [ ] PRO-CUT 55 OUTPIUT
J33
X2
(B12)
x40
B1
B2
x20
R5
R5
Test
Point
J31
J32
TEST PROCEDURE
1. Remove input power to the Pro-Cut 55
machine.
2. Perform the Input Filter Capacitor
Discharge Procedure detailed earlier in this
section.
3. Remove the torch assembly from the
machine.
PRO-CUT 55
4. 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 B11
Diode A1
and
associated trace
Less than
100 ohms
+Probe Terminal B11
to
–Probe J33-Pin4
Diode A1
and
associated trace
Greater than
1000 ohms
+Probe J33-Pin4
to
–Probe Terminal B12
Diode A1
and
associated trace
Less than
100 ohms
+Probe Terminal B12
to
–Probe J33-Pin4
Diode A1
and
associated trace
Greater than
1000 ohms
+Probe R5 Test Point
to
–Probe Terminal B1
Diode A2
and
associated trace
Less than
100 ohms
+Probe Terminal B1
to
–Probe R5 Test Point
Diode A2
and
associated trace
Greater than
1000 ohms
+Probe R5 Test Point
to
-Probe Terminal B2
Diode A2
and
associated trace
Less than
100 ohms
+Probe Terminal B2
to
–Probe R5 Test Point
Diode A2
and
associated trace
Greater than
1000 ohms
+Probe R5 Test Point
to
–Probe J32-Pin14
Transistor A2
and
associated trace
Less than
100 ohms
+Probe J32-Pin14
to
–Probe R5 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.
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.
EXPECTED RESISTANCE
8. Reconnect the leads and plugs previously
removed.
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 216-383-2531 or 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
5/16” Nut driver
Volt/ohmmeter
12 VDC @ 1 Amp Power Supply
This procedure takes approximately 15 minutes to perform.
PRO-CUT 55
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 55
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 55
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 216-383-2531 or 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 55
F-25
TROUBLESHOOTING & REPAIR
F-26
AIR/GAS SOLENOID TEST (continued)
FIGURE F.6 – AIR SOLENOID
AIR SOLENOID
TEST PROCEDURE
See the Wiring Diagram. If the leads are
good, the solenoid coil may be faulty.
1. Remove input power to the machine.
2. Perform the Input Capacitor Discharge
Procedure detailed earlier in this section.
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).
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.
With proper air pressure applied, the solenoid should activate and air should flow.
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.
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
(B11)
G3326 - [ ] PRO-CUT 55 OUTPIUT
J33
X2
(B12)
x40
B1
B2
R5
Test
Point
x20
R5
F-26
J31
J32
PRO-CUT 55
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 216-383-2531 or 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 55
F-27
F-28
F-28
TROUBLESHOOTING & REPAIR
(T2) AUXILIARY TRANSFORMER TEST (continued)
FIGURE F.8 – T2 AUXILIARY TRANSFORMER
5
4
9
8
2
6
PLUG J21
PLUG J21
PLUG J22
T2 AUXILIARY
TRANSFORMER
6
3
4
1
PLUG J22
PROCEDURE
1. Remove main input power to the Pro-Cut 55
machine.
2. Perform the Input Filter Capacitor
Discharge Procedure detailed earlier in this
section.
3. Locate the auxiliary transformer just behind
the input line switch on the lower right side of
the machine.
4. Locate and disconnect plugs J21 and J22
from the wiring harness. Cut any necessary
cable ties. See Figure F.8.
PRO-CUT 55
5. Carefully apply the 230 VAC isolated supply
to leads H1 (1J22) and H3 (2J22) of the auxiliary transformer. These leads are located in
plug J22.
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 (1J22)
H1 (1J22)
H1 (1J22)
Brown (8J21)
Red (2J21)
Blue (9J21)
Blue (4J21)
TEST POINT
H2 (4J22)
H4 (3J22)
H5 (6J22)
Brown (3J21)
Red (6J21)
White (5J21)
White (5J21)
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
9. If the auxiliary transformer tests good but it
does not function when connected to the
Pro-Cut 55, check the harness wiring to the
auxiliary transformer.
See the Wiring
Diagram.
10. When finished with the test, replace plugs
21 and 22 and the case wraparound.
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 216-383-2531 or 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 55
F-30
F-31
F-31
TROUBLESHOOTING & REPAIR
TRIGGER CIRCUIT TEST (continued)
FIGURE F.9 – SIMPLIFIED TRIGGER CIRCUIT DIAGRAM
OUTPUT BOARD
CONTROL BOARD
+17VDC
+15VDC
TORCH
RECEPTACLE
9
#4
1J31
#2
2J31
TRIGGER SWITCH
IN TORCH HANDLE
1
3J32
#344
11J3
14J32
#312
12J3
D25
AUX
COM
PROCEDURE
1. Remove input power to the Pro-Cut 55
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 Pro-Cut
55. 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 55
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#344) (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#344) (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 55.
10. Perform the Input Filter
Discharge Procedure.
Capacitor
11. Check the continuity of leads #344 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.
F-32
F-33
TROUBLESHOOTING & REPAIR
F-33
TRIGGER CIRCUIT TEST (continued)
FIGURE F.10 - OUTPUT BOARD TRIGGER CIRCUIT TEST POINTS AND LEDS
G3326 PRO-CUT 55 OUTPUT
LED3
LED5
J31
LEAD#2
LEAD#4
LEAD#312
J32
LEAD#344
LED1
D25
LED4
C13
J30
+
LED2
PRO-CUT 55 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.
F-34
TROUBLESHOOTING & REPAIR
TRIGGER CIRCUIT TEST (continued)
FIGURE F.11 - CONTROL BOARD LEDs
PRO-CUT 55 CONTROL 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.
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 216-383-2531 or 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 55
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
PLASMA
OUTPUT
BOARD
H2
24VAC
2
#51 1J30
RED
6
#54 4J30
BLUE
4
#61 1J1
=28VDC
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 55
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.
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.
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.
4. Check for the presence of approximately 28
VDC on the output board.
7. Check for the presence of -15 VDC on the control board.
a. LED1 should be lit when 28 VDC is present.
See Figure F.13. See Output Board LED
Definitions and Figure F.12, Low Voltage
Circuit Diagram.
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.
b. To verify the presence of 28 VDC, check
across capacitor C13. Make certain the
voltmeter probes make good contact with
the capacitor leads. See Figure F.13.
PRO-CUT 55
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.
F-37
F-38
TROUBLESHOOTING & REPAIR
F-38
LOW VOLTAGE CIRCUIT TEST (continued)
FIGURE F.13 – OUTBOARD LOW VOLTAGE CIRCUIT TEST POINTS AND LEDs
G3326 PRO-CUT 55 OUTPUT
LED3
J31
LED5
PIN-6
J32
LED1
D25
LED4
C13
J30
+
LED2
PRO-CUT 55 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 55
F-39
TROUBLESHOOTING & REPAIR
F-39
LOW VOLTAGE CIRCUIT TEST (continued)
FIGURE F.14 – CONTROL BOARD LEDs
PRO-CUT 55 CONTROL 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 55
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 216-383-2531 or 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 55
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 55
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 55
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.
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 216-383-2531 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 55
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 55
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 55
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 55
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 216-383-2531 or 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.
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 55
machine.
2. Remove the case wraparound and perform
the Input Capacitor Filter Discharge
Procedure detailed earlier in this section.
3. Locate the output power P.C. board and
associated lead and plug connections. See
Figures F.21 and F.22.
F-48
TROUBLESHOOTING & REPAIR
F-48
OUTPUT POWER BOARD REMOVAL & REPLACEMENT (continued)
FIGURE F.22 – OUTPUT BOARD LEAD LOCATIONS
x4
G3326 - [ ] PRO-CUT 55 OUTPIUT
J33
x40
B1
B2
x2
x20
B21
J31
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 and J33 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 two screws from the lower 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.
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 two phillips head screws previously removed.
5. Replace leads X20 and X40.
6. Replace plugs J30, J31, J32 and J33.
7. Replace leads X4 and X2.
8. Replace lead B21 and torque it to 70 inchpounds.
9. Clear and secure all leads and replace the
wraparound cover.
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 216-383-2531 or 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
Slot-Head screw driver
Torque wrench
3/8” Wrench
Penetrox A-13 (Lincoln E2529) Electrical Joint Compound
This procedure takes approximately 40 minutes to perform.
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 55
machine.
2. Remove the case wraparound and perform
the Input Filter Capacitor Discharge
Procedure detailed earlier in this section.
3. Locate the primary power board and associated lead and plug connections. See Figure
F.23.
4. Label the leads for reassembly.
5. Remove Plug J10.
6. Using the 7/16” wrench, remove leads 201,
202A, 203A, 204, 205, 206, 207A, 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
CAPACITOR
CLAMP
PRIMARY
POWER
P.C. BOARD
7/16"
CAPACITOR
BOLT (4)
3/8" MOUNTING
INSULATOR (2)
MOUNTING
SCREW (2)
7. Using the slot-head screw driver, remove the
two mounting screws from the left side of the
primary power board. See Figure F.24. Take
note of insulator placement for reassembly.
8. Using the 3/16” allen type wrench, remove
the four socket head screws and lock washers mounting the primary power board to the
heat sink.
SOCKET
HEAD
SCREW (4)
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 assembly to the
upper and bottom sections of the machine.
See Figure F.24.
2. Remove the gas hose restraints from the bottom of the heat sink assembly.
3. Remove the two thermostat leads from the
thermostat, which is located next to the
upper capacitor.
4. Carefully remove the heat sink and capacitor
assembly. Clear any necessary leads.
5. Remove the faulty capacitors by using the
slot head screw driver to loosen the clamps.
Take note of capacitor position in the clamp.
Observe polarity markings and terminal
position.
CAPACITOR REPLACEMENT AND
P.C. BOARD REPLACEMENT
1. Replace the capacitors by positioning them
in the clamps. Do not tighten the clamps.
They must be loose when the P.C. board is
assembled to the capacitors.
2. 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.
3. 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.
4. Assemble the four socket head screws and
pre-torque them to 25 inch-pounds.
5. 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.
6. Finish tightening the four screws to 40-48
inch-pounds.
7. Assemble the two slot head screws with
their appropriate insulators.
8. Tighten the capacitor clamps.
9. Place the assembly into the machine and
connect the two thermostat leads previously removed.
10. Secure the assembly to the upper and bottom sections of the unit using the 3/8”
wrench and the four screws previously
removed.
11. Connect the J10 plug.
12. Connect leads 201, 204, 205, 208 and 209
previously removed.
13. Connect leads 202A, 207A, 206, and 203A
to the capacitor terminals. Torque to 50-60
inch-pounds.
14. Replace the gas hose restraints previously
removed.
15. Clear and reposition any leads that may be
disturbed.
16. 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 216-383-2531 or 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
Essex DC-4-8 (Lincoln E3539) Electrical Insulating Compound
This procedure takes approximately 16 minutes to perform.
F-54
F-55
TROUBLESHOOTING & REPAIR
F-55
INPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued)
PROCEDURE
1. Remove input power to the Pro-Cut 55.
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.
CAP HEAD
MOUNTING
SCREW
#207
#207A
A
B
C
#209
FIGURE F.25 – INPUT RECTIFIER LEAD LOCATIONS
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 Essex DC-4-8 Insulating Compound to all six screw heads and terminals. The heavy input lead terminals
should be against the rectifier terminals.
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
230/60
0.42
98
Output Current Range
25 - 55 Amps
Maximum Open Circuit Voltage
335 Volts
PRO-CUT 55
F-58
NOTES
F-58
G-1
ELECTRICAL DIAGRAMS
TABLE OF CONTENTS
ELECTRICAL DIAGRAMS SECTION
Electrical Diagrams Section ..........................................................................................Section G
Wiring Diagram (208V, 230V, 460V) (L10634) ............................................................................G-2
Plasma Output Board Schematic (L10722) .................................................................................G-3
Power P.C. Board Schematic (L10616) .......................................................................................G-4
Display P.C. Board Assembly (L10721-1)....................................................................................G-5
Display Board (M18920) ..............................................................................................................G-6
Control Schematic (G3327) .........................................................................................................G-7
Control P.C. Board Assembly (G3328-1) .....................................................................................G-8
Control P.C. Board Assembly (G3328-2) .....................................................................................G-9
Output P.C. Board Assembly (G3326-1)....................................................................................G-10
Output P.C. Board Assembly (G3326-2) ....................................................................................G-11
Power P.C. Board Assembly (G3172-1) ....................................................................................G-12
Power P.C. Board Assembly (G3172-2) ....................................................................................G-13
PRO CUT 55
G-1
XFER
B21
CHOKE
1
2
3
4
2
3
5
6
E
1
4
53
54
56
51
G
7
14
312
6
310
5
303
309
12
9
361
316
13
2
8
365
315
1
4
5
2
4
360
11
4
9
10
364
369
366
344
3
404
507
3
2
7
8
W
R
W
R
503
506
505
10
1
6
X20
X40
401
S
12V
1,4=24V
J30
14 GND
13 IGBT
1,4 VFB
3 TRIGGER
2 ELEC SOL
8 AIR SOL
J32
10 WORK
7,8 ELEC SOL
5,6 AIR SOL
4 ELECTRODE
3 NOZZLE
1,2 TRIGGER
J31
XFER
ELEC
J33
J10
3
502
2
5
6
501
1
4
TRANSFORMER
CURRENT
T3
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.
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.
OUTPUT
X2
X4
201
P_XFMR
++VOLT
RELAY
205
209
xxxxxxx
N.D. C1 AND C2 CAPACITORS ARE A MATCHED SET.
CONNECTION SHOWN IS FOR 440-460V OPERATION.
N.C. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE.
COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER.
THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT
N.B. SINCE COMPONENTS OR CIRCUITRY OF A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING
N.A.
MOTORS
H1
-
C2
1200/450
+
207A
POWER
206
ELEC
NOTES:
FAN
FAN
FAN
H3
202A
204
208
203A
-
1200/450
208
204
Y
Y
T
U
-O
K
B
C1
S
A
X4
K
-I
N
K
-O
X40
B
U
T
F
R
F
R
-
-O
U
T
BRIDGE
D1
INPUT
PC BOARD
A
A
TP2
B
TP1
C
H1 H1
203A
206
202
CASE FRONT
TP3
3
6
Y
505
506
R
W
312
R
302
303
P_XFMR
212
J20
4
S3
275
221
PSI_SET
277A
S1
R1
277B
C POWER
217
10
9
8
7
6
5
4
3
2
J40
302
215
214
213
210
223
276
275
215
12
1
200230VAC
9
2 10
3 11
4
5 13
9 AIR SOL
10 ELEC SOL
2,6 PSI SWITCH
3 IGBT
11 TRIGGER
12 GND
J3
E
S5
3
J2,J8,J31
4
6
7
2
8
1
2
J7,J30
J4,J6,
364
369
W
11
J5
WORK
DISPLAY
PSI SET
RESET LED
THERMAL LED
GND
RESET
POT WIPER
LOW_PSI LED
READY LED
+15V
J40
1
2
3
4
5
6
7
8
9
10
S2
RESET
J32
(VIEWED FROM COMPONENT SIDE OF BOARD)
FRONT OF MACHINE
L10634
1-23-98F
COLOR CODE:
B = BLACK
G = GREEN
R = RED
W = WHITE
U = BLUE
N = BROWN
Y = YELLOW
CONNECTOR CAVITY NUMBERING SEQUENCE
J1,J20
9
4
AIR
PRESSURE
SOLENOID
N
W
R
POT
CW (MAX)
361
1
Y
10K
2W
CONTROL
366
N
306
2
277
277A
276
221
5
210
219
218
217
214
219
213
277
CONTROL
J2
J1
12
13
15
14
216
223
218
216
B
U
212
1
R
B
V
2
A
W
W
4
18V
G
8 16
15,16 VFB
TSTAT
CT
RELAY
++VOLT
3
1
18V
61
7 15
6 14
400460VAC
309
310
344
W
150
306
316
315
J3
5
4
1
6
J4
2
3
5
7
6
2
1
3
J5
4 8
61
5 62
W
U 4
J21
64
9
U
51
54
6
2
R
R
53
56
3
8
N
N
TRANSFORMER
T2
507
Y
18V
18V
24V
12V
AUXILIARY
H5
H4
H3
H2
H1
404
401
501
502
503
J22
2
4
1
62
64
ELECTRICAL SYMBOLS PER E1537
PROTECTIVE BONDING CIRCUIT
BASE
203
207
RECONNECT
S4 PRIMARY
A
B
C
LEFT SIDE OF MACHINE
203
202
X20
X2
XFMR
MAIN
T1
202A
R
D
F
B
N
-I
F
SF R
X30
OUTPUT
460V
415V
230V
A
IN
NN
W
X3
S
360
220-
H3
H5
T
440-
H4
H2 H3
U
365
X10
X1
S
-O
201
0.6A
SLOW BLOW
B
7
2
6
205
209
207A
207
RIGHT SIDE OF MACHINE
380-
208V
200-
N.C.
A
S
3
S
+
INPUT
PER
N.A.
S
I
N
S
S
I
-I
+
S
K
-
NOTE:
S
B
G-2
ELECTRICAL DIAGRAMS
G-2
Wiring Diagram (208V, 230V, 460V) (L10634)
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.
L10634
8-7-98A
REAR OF MACHINE
J33
4
2
AUX
6
4
AC POWER
3
1
J30
BOARD
TO: CONTROL
3
1
+15V
511
10
8
5
10
6
CHASSIS
SOLENOID,
5
TO: TORCH,
15W
15W
C30
14
8
TO: CONTROL BOARD
7
J32
15J
3
A
8
5
-2V
GND
HP2201
OCI1
Vcc
+15V
AUX
1W
12V
DZ8
C20
POWER
SUPPLY
C23
AUX
35V
1000
D5
D3
+17V
4
50V
D4
D2
6
5
C18
AUX
3000V
.0047
C27
3000V
.0047
50V
820p
C12
OCI2
CNY17-3
2
1
+17V
TP5
A
COM
D10
1
J30
J30
J30
J32
FEEDBACK
VOLTAGE
REMOTE
C
A1
4
2000V
.0015
C15
1200V
45A
Q6
9
10
11
12
2
6
LED2
J32
J32
J32
J32
J34
J34
5
9
1
4
5
6
7
100V
1A
Q3
J30
J31
J32
J32
J32
J32
J32
G
1000V
3A
D27
ISOLATION BETWEEN CIRCUITS ( MINIMUM 0.20'' )
1.5K
1.5K
R53
15W
R52
1.5K
CIRCUIT (AIR)
8
A
R51
1
15W
4
3
C
A1
2
1.5K
J34
J34
R3
SOLENOID ENABLE
A
R50
180J
180J
NOZZLE
480V
TP1
480V
480V
180J
TP3
ELECTRODE
1000V
3A
D28
2000V
.0015
R8
C3
10W
160
10W
160
R6
TP2
1
J31
TO: AMPHENOL
4
J34
6
3
2
1
12VAC
XFMR
ON = ENABLE
BOARD
CONTROL
ENABLE FROM
SOLENOID
J31
B11
B12
R4
1.50K
LED3
C
E
N.A.
5W
25
R5
D25
TO
TRIGGER
600V
.05
C31
60V
.13
+t
R15
+t
60V
.13
REMOTE
1400V
.0047
C9
PILOT
1W
5
1
J31
J31
5
6
J34
J34
R19
0.001
C29
.1
1000V
C7
.1
1000V
C6
.1
1000V
1W
DZ2
1W
15V
DZ1
15V
R14
G
15V
1% 13W
A
C5
.1
1000V
6
LED6
C
A2
7
B1
DZ10
1W
15V
DZ9
PILOT
P4
100
4
C
A2
E
C
TRIGGER
SOLENOID
AIR
R18
0.001
A
A2
5
B2
(26:26)
+15V
.0015
C1
24VAC
XFMR
1% 13W
2
BOARD
CONTROL
ON = ENABLE
J31
1
SOLENOID
ENABLE FROM
J31
+15V
ON = ENABLE
BOARD
CONTROL
ENABLE FROM
PILOT
AUX
1000V
3A
D29
2000V
S1 PILOT WINDINGS
28mA
5.6mH
L1
+t
2
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE
NUMBER.
D9
D16
3
2
D17
50V
50
C13
D15
COM
HP2201
OCI1
D14
3A
600V
D18
D24
3A
600V
10W
160
NOZZLE
D7
D6
D1
COM
50V
0.1
C28
AUX
+17V
J32
AUX
D11
D8
OCI3
6
CNY17-3
2
1
D23
8.25K
R57
1400V
.0047
C21
4
5
C25
1A, 400V
R30
Q5
G
1.21K
R29
35V
27
C16
50V
820p
C8
UNLESS OTHERWISE SPECIFIED)
DZ6,R40,R41,R42,R43,R44,R45,R46,R47,R47,R48,R49
Unused reference designators: C4,C26,DZ4,DZ5,
55 AMP PLASMA CUTTER
2
1
Q4
4A
100V
OCI4
6
CNY17-3
+17V
LED5
S
D
1N4936
D22
-2V
50V
820p
C19
D13
7
8
J31
COM
4
5
J32
OUT
600V
.05
C32
60V
.13
+t
R17
+t
60V
.13
R16
4
2
14
1
3
GND
INV IN
N.I. IN
Vin + Vc
TRIGGER SIGNAL
3
2
1
5
4
SIGNAL
32
5
12
DZ-
VOLTAGE NET
OCI- 4
TP-
8
7
1
8
LED-
X-
Q-
CHOKE
6
EARTH GROUND CONNECTION
FRAME CONNECTION
COMMON CONNECTION
POWER SUPPLY SOURCE POINT
SUPPLY
30
61
CD-
R-
LAST NO. USED
= TRIGGER OFF
LABELS
OPEN
SHORTED = TRIGGER ON
J31
J31
CONTROL BOARD
SIGNAL TO
TRANSFER SHUNT
CONTROL BOARD
SIGNAL TO
ELECTRODE SHUNT
X1
B21
(ELECTRODE)
OK TO MOVE
REMOTE
4
TO CONTROL BOARD
3
D26
1400V
.0047
C10
J33
J33
COM
J32
J33
J33
C22
+15V
PILOT DRIVE
PILOT
100V
1A
Q8
J34
J34
ELECTRODE
UNLESS OTHERWISE SPECIFIED)
AUX
2N4401
LED4
CIRCUIT
100V
1A
Q1
+15V
1W
12V
DZ12
PILOT
(UNLESS OTHERWISE SPECIFIED)
1/4W
MFD ( .022/50V
FILE NAME: L10722_2BC
DIODES =
RESISTORS = Ohms (
CAPACITORS =
ELECTRICAL SYMBOLS PER E1537
R20
D21
5W
15V
DZ3
100V
1A
Q7
4.75K
D20
2.00K
TRIGGER
AUX
1W
12V
DZ7
7
-2V
R35
10W
100
D19
50V
100
C14
C24
HP2201
OCI1
LED1
1W
12V
DZ11
R60
1.00K
+17V
R22
GENERAL INFORMATION
+17V
50V
820p
C17
CIRCUIT (ELECTRODE)
60V
.13
J32
J30
20J
75V
TP4
J30
15W
2.5K
15W
2.5K
J31
(NOZZLE)
SOLENOID ENABLE
R33
13
4
1
3
WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY
SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE
NOTES :
S
Q2
4A
100V
1N4936
D
3A
D30
2000V
PILOT DRIVE
D12
35V
C2
1.0
G
C11
.0015
1000V
511
R38
R39
(26:24)
R12
221K
3.92K
R13
1.50K
475
R2
R21
S2 MAIN WINDING
R11
1.00K
(WORK)
R10
1.21K
R36
10W
160
160
10W
R55
R1
R37
10W
160
10W
160
511
R25
R23
P3
511
5.11K
R32
P2
332
P1
R7
3.74K
3.74K
R58
3.32K
R26
221K
R61
R34
R24
R59
1.50K
475
3.92K
R27
1.50K
R54
R31
1.21K
R28
2.00K
R56
1.21K
825
MAIN
R9
TRANSFORMER
221K
ELEC
SOLENOID
G-3
ELECTRICAL DIAGRAMS
G-3
Plasma Output Board Schematic (L10722)
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.
L10722
5-29-98D
PRO CUT 55
G-4
ELECTRICAL DIAGRAMS
Power P.C. Board Schematic (L10616)
1.00K
209
10W
5W
4A
5
4
6
C5
1.00K
5W
2.7
1A
.0047
R24
1000V
50V
R26
R23
R22
R21
1.00K
1.00K
R112
1K
1K
5W
5W
X1
-
27
REF
35V
6
1W
1W
C16
1.0
1000V
13
G3
C4
15
TRANSFORMER
16
G4
E3
11
PRIMARY
E4
14
K1
10
6
1
R62
E2
4
R101
FILTER
CAPACITOR
R104
PRIMARY
1K
5W
5W
1.00K
1.00K
R66
1.00K
R64
R63
DZ14
1.00K
R65
1W
C11
.0047
50V
D11
2.7
5W
1K
5W
5W
R84
R85
150K
332K
10.0K
15.0K
2.7
5W
EARTH GROUND CONNECTION
TO CONTROL BD.
4
150p
50V
+15V
J10
2
+15V
1.0
1W
Q2
C13
1A
9
100V
Q3
50V
15V
6
D13
0.27
1A
1000V
6.19K
R97
1K
2
3
C10
R83
R106
R69
R68
10.0
15V
CNY17-3V
1
R92
5W
R103
1K
R105
R46
DZ13
R90
1K
C12
TRANSFORMER
OCI2
X3
D14
5
5
2
7
X3
201
1000V
6.2V
1W
(NOMINAL)
.0047
10.0
DZ12
1
R61
E1
15.0K
221K
G2
6.19K
J10
DZ8
15V
CW
R81
16.5K
2.21K
5
332K
1.00K
R54
C2
150K
5W
13.7K
G1
R91
1A
2.21K
3
R89
R113
C1
2
R88
5
1.82K
7
R87
1K
2.94K
9
A2
325VDC
R102
A1
R86
6
R100
8
D12
+15V
R99
K2
10.0
TEST_A
12
V/F CONVERTER
100V
1.00K
10.0
R82
C3
FRAME CONNECTION
COMMON CONNECTION
POWER SUPPLY SOURCE POINT
T- 1
VOLTAGE NET
DZ17
X-
5
Q-
1A
204
.0047
TEST_E
R19
Q4
35V
C9
R60
DZ16
5.1V
A1
R55
R70
5W
1W
R95
50V
15V
221K
2.7
R96
1000V
.0047
14
150K
NOTES :
1A
C8
1.00K
R45
1.00K
R44
1.00K
R43
R42
1.00K
1.00K
1W
X2
13
R57
D10
15V
DZ11
D17
12
D1
D4
8
9
DZ10
D5
150K
10
X2
22.1K
DZ9
221K
2
R51
1.00M
5W
R67
1W
(PWM DRIVE)
2.7
1
X2
R114
10.0K
10.0
6.2V
R49
BOARD
G4
R40
GATE
7
3
10.0K
RECONNECT
1.00M
6.19K
7.68K
TEST_B
R41
S4
R48
CONTROL
10.0
G3
R115
10.0K
PROTECTION
R71
GATE
6
+15V
R52
S3
R53
MISCONNECTION
202A
R50
4
12
OVERVOLTAGE
+15V
RECONNECT
GATE
9
FROM
35V
203A
S1
R47
3
27
562
PROTECTION
10 S2
DRIVE
J10
C20
5W
R56
6
D3
C7
8
2.7
G2
1
221K
6
3
J10
7
X2
2.8K
15V
G1
GATE
8
1.00K
DZ7
5
T1
R27
D9
1W
R111
1
TL431
10.0
15V
5W
1000V
R79
DZ6
5W
+
NUMBER.
6.2V
1W
1K
8
X3
10
100V
1W
10K
.0047
R109
1K
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE
C6
DZ5
R110
WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY
208
R28
4
10.0
5
R94
47.5K
R33
1
E2
R116
1.00M
5W
R38
E1
+15V
1K
SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE
G2
TEST_C
TRANSFORMER
PRIMARY
N.A.
5
D2
CAPACITOR
3.32K
C2
5W
3.32K
C1
G1
GENERAL INFORMATION
(NOMINAL)
2
1K
R37
A2
7
FILTER
7.68K
325VDC
R39
6
R20
9
10.0K
3
8
A1
R75
10.0
R6
K2
150K
10
+15V
R34
K1
10.0
PRIMARY
150K
E4
14
R35
11
R36
15
E3
1W
6.19K
C4
G4
25V
R76
G3
16
12V
R107
13
TRANSFORMER
50V
C15
50
DZ15
R108
R25
12
20
2
150p
C3
117
CNY17-3V
12V
1W
C4
A2
R-
R18
1
OCI1
DZ4
900V
PRECHARGE
R32
R31
22.1K
221K
R30
221K
205
1000V
R29
1W
R17
221K
.0047
100
Q1
CAPACITOR
C2
50V
221K
.0047
1.00K
R72
FILENAME:L10616_2CA
100
10W
(UNLESS OTHERWISE SPECIFIED)
R12
100
10W
UNLESS OTHERWISE SPECIFIED)
R11
100
1000V
C1
15V
R10
1/4W
1A
D15
150K
1A, 400V
1.00K
R5
R3
DZ3
1.00K
R7
1.00K
R2
1.00K
R4
1W
PEAK DETECTOR
2.7
150K
DIODES =
5W
D8
R15
150K
RESISTORS = Ohms (
2.7
10.0
R14
150K
UNLESS OTHERWISE SPECIFIED)
R80
15V
R16
R13
MFD ( .022/50V
R8
DZ2
4
POSITIVE INPUT RECTIFIER
5
10.0
DZ1
1W
150p
50V
CR1
6
6.2V
J10
C17
LABELS
1A
100V
3
206
16
Q5
CAPACITORS =
4
FROM CONTROL BD.
2
221K
15V
CR1
TEST_D
R1
18
35V
1.00M
6
C18
C19
1.0
R117
RECONNECT
(RELAY DRIVE)
D7
1
4
SUPPLY
A- 2
2
CR1
CNY17-3V
12
11
CR- 1
1
LAST NO. USED
1
C-
OCI3
R77
22.1K
X3
LM224
11
R98
4.75K
14
5
R74
LM224
13
D16
X3
R78
C14
X2
R93
C3
18.2K
4
7.68K
4
J10
R73
PROTECTION
D-
+15V
UNDERVOLTAGE
3
+15V
ELECTRICAL SYMBOLS PER E1537
+15V
D6
1W
207A
NOTE: 202,203,206,&207 BOLT ON WITH FILTER CAPS
NEGATIVE
INPUT RECTIFIER
300 Volts = 1kHz (calibrated)
dF = 9.5136 dV
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.
L10616
5-29-98H
PRO CUT 55
G-5
ELECTRICAL DIAGRAMS
G-5
DISPLAY
Display P.C. Board Assembly (L10721-1)
L10721-1
NOTE:
ITEM
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
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.
L10721-1
1-9-98M
SIGNAL
"SAFETY"
SIGNAL
"THERMAL"
SIGNAL
"AIR LOW"
SIGNAL
"READY"
8
9
13
14
10
15
J40
J40
J40
J40
J40
J40
C1
35V
C5
4.7
COM
+15V
50V
2700p
C4
R13
3.32K
50V
2700p
C3
R9
3.32K
50V
2700p
C2
R5
3.32K
50V
2700p
R1
3.32K
2N4401
Q1
2N4401
Q2
R2
2N4401
Q3
R6
2N4401
Q4
R10
R14
6.81K
6.81K
6.81K
6.81K
COM
COM
COM
COM
R16
75.0
75.0
R12
R11
R15
100
R8
R7
100
100
R4
R3
100
100
100
+15V
+15V
2
3
4
5
6
7
4
2
2
3
4
5
6
7
4
2
1
1
1
8
3
8
3
1
LED6
LED8
HLMP-2855
HLMP-2350
LED3
LED4
HLMP-2755
HLMP-2350
5
5
7
7
N.A.
4
2
7
6
5
4
3
2
4
2
7
6
5
4
3
2
1
1
3
8
1
3
8
LED9
LED7
LED5
LED2
5
5
7
7
6
8
6
8
R20
243
2
3
1
4
+15V
LED1
HLMP-2400
NUMBER.
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE
WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY
SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE
NOTES :
6
8
6
8
1
J40
J40
+15V
DIODES =
6
J40
J40
J40
J40
4
3
1
2
5
UNLESS OTHERWISE SPECIFIED)
COM
J40
J40
(UNLESS OTHERWISE SPECIFIED)
1/4W
+15V
825
UNLESS OTHERWISE SPECIFIED)
1W
10V
DZ1
MFD ( .022/50V
1A, 400V
RESISTORS = Ohms (
CAPACITORS =
ELECTRICAL SYMBOLS PER E1537
GENERAL INFORMATION
FILENAME: M18920_1AA
12
11
7
J40
+15V
2.67K
HLMP-2550
HLMP-2655
HLMP-2450
HLMP-2655
R18
R19
R17
NOTE:
2.67K
15
14
13
12
11
10
9
8
7
6
5
C-
R-
LED-
DZ- 1
9
4
3
2
EARTH GROUND CONNECTION
FRAME CONNECTION
COMMON CONNECTION
POWER SUPPLY SOURCE POINT
VOLTAGE NET
5
20
LAST NO. USED
J40
POT
CONTROL
SUPPLY
LABELS
RESET
AIR SET
10K
1
G-6
ELECTRICAL DIAGRAMS
G-6
Display Board (M18920)
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.
M18920
10-31-97D
G-7
ELECTRICAL DIAGRAMS
Control Schematic (G3327)
J4
10p
100V
R159
1.21K
5
ISOURCE
GND
6
NC
7
NC
TACH INPUT
IBIAS
V+
ISINK
C40
35
ELECTRODE_SOLENOID
PA7
27
PRIMARY_POWER
PB0
42
READY
PC0
PB1
41
SAFETY
AIR_LOW
THERMAL
7
COM
COM
10
R95
COM
+5.5V
R173
PA1
33
ELECTRODE_AMPS
45
PE1
/RETRACT_ARC
32
PA2
PD0
20
3.74K
15
PC6
PD1
21
R100
36
PB6
MODA
3
40
PB2
PB5
37
23
PD3 (MOSI)
PC2
11
24
PD4 (SCK)
PE5
46
25
PD5 (CS_D/A)
PE6
48
PD2 (MISO)
PE7
50
Vdd
PE3
49
22
68HC711E9
SENSE_AMPS
COM
ELECTRODE SOLENOID
R183
R188
+15V
39.2K
DZ4
C76
1.0
5.1V
1W
50V
R174
7.68K
C18
6.81K
+15V
4
2
V EE
OP27
OUT
6
NC
5
R28
6
3.32K
10K
X1
LT1014
0.1
5
7
221
47.5K
C17
1.0A
COM
30V
1
100K
R2
5
+15V
7
C68
C69
7
4
/PIP
221K
R82
X6
X3
C63
C64
4
4
9
R83
TCF6000
COM
C2
OP27
C8
X2
X1
X4
OP27
8
LM224
POWER
TO: DISPLAY
SUPPLY
1
J1
TO: OUTPUT
BOARD
BOARD
2
1
J2
TO: CT &
5
1
J3
TSTATS
8
1
J4
150p
50V
BOARD
3
1
J5
4
COM
R79
221K
3
4
6
10
9
16
4
6
5
8
R80
7
4
.47
D23
LT1014
11
COM
C65
C66
33074A
R177
R176
R175
511
R10
R8
C10
X3
X12
LM224
11
SG3846
11
12
-15V
14
1
16
15
8
COM
8
Vdd
26
C19
4.7
35V
C41
X16
TCF6000
1
X10
TCF6000
C24
X5
9
C25
4.7
35V
C34
68HC711E9
Vss
1
COM
1
X18
LM2907
12
C73
GENERAL INFORMATION
LAST NO. USED
R-
ELECTRICAL SYMBOLS PER E1537
CAPACITORS =
MFD ( .022/50V
RESISTORS = Ohms (
DIODES =
1A, 400V
1/4W
UNLESS OTHERWISE SPECIFIED)
(UNLESS OTHERWISE SPECIFIED)
FILENAME: G3327_2C1
R 15,R16,R25,R41,R50,R60,R64-R66,R71,R74,R75,R86,R90,R92,R148,R150,R151,R161-R163
D24,X17
C-
UNLESS OTHERWISE SPECIFIED)
C11,C12,C27,C38,C49,C51,C67,C70
LABELS
D-
SUPPLY
196
X-
76
Q- 5
27
DZ- 4
18
Y-
1
TP-
2
LED-
3
VOLTAGE NET
POWER SUPPLY SOURCE POINT
COMMON CONNECTION
FRAME CONNECTION
EARTH GROUND CONNECTION
X16
2
COM
ELECTRODE
SHUNT
L1
PILOT
DIODES
REF. DESIGNATORS SKIPPED:
13
J3 J3 J3 J3 J3
50V
COM
+5.5V
13
COM
COM
5
R84
6
C4
R81
10.0K
10.0K
X3
LM224
5.11K
C22
1.21K
TO: POWER
14
13
5
1V = 68.07mA
R85
R78
R9
+15V
4
C20
COM
10
NOZZLE
PILOT
WINDINGS
33074A
7
COM
C75
5
6
18.2K
WORK
+5.5V
MS-001BA
X2
100K
X1
WINDINGS
COM
D7
X16
LT1014
COM
CALIBRATION
2
+15V
1.30K
12
CUT
POWER SUPPLY
-15V
OUT
X2
2700p
50V
THERMAL
D
CUT
DIODES
50V
X15
R89
COM
4
J2
TRANSFER
SHUNT
LED3
COM
C45
243
LED2
100
RESISTORS MAY NOT BE PRESENT
35V
LED1
C5
SOME OR ALL OF THESE
3
33074A
50V
R
1.30K
D21
150p
R97
R46
COM
475
7
C31
COM
82.5K
C37
243
R26
2.67K
R30
1.30K
R98
8
C44
10.0K
COM
R32
X9
D4
9
50V
J3
7
X1
D9
7915
2.43K
LT1014
R48
R24
NOTE:
D8
27
GND
IN
D3
R18
221
R35
35V
C9
50
50V
J1
4
V_PWM
10
R88
INPUT
I_SET
GAIN = 80.0
CW
O
MACHINE OVERVIEW
1000
C7
TP2
50V
1V = 12.50 A
R40
7
GND
C3
50V
15J
R21
SHUNT
4
7.68K
8
OUT
S18395-13 ASSY
J1
18VAC
1.00K
10.0K
C36
C16
R27
2
243
V CC
IN
ADJ
50V
15J
NULL
B
-15V
ELECTRODE
R194
3.92K
R193
3.92K
X16
X4
AIR_LOW
2
X8
OUT
S18647 ASSY
3300
TP1
18VAC
CT
+5.5V
C1
1K
TCF6000
+15V
1.00K
X7
IN
J1
1
R192
NULL
Y
J2
3.32K
D6
243
XFMR
PIP
A
7805
LM350
R7
5W
D2
CW
INPUT
+5.5V
D5
AUX
3
L
10
R118
12
1
S
A
SENSE_AUX
POWER SUPPLY
READY
I
J2
3.32K
18.2K
3.32K
R1
243
D
7
P
D1
R36
DISABLE
J2
3.32K
R117
+15V
R33
PRE-CHARGE
COM
J3
ELECTRODE
7.68K
R116
1.0
J3
G
COM
COM
COM
8
J5
Q4
4A
100V
R109
9
50V
COM
COM
1400V
5
2.00K
R93
243
.47
ELECTRODE_AMPS
R37
C35
.0047
D
3.92K
D14
1.50K
R103
10.0K
COM
R38
1.00K
243
J3
4
X2
33074A
R6
R73
LT1014
8
R104
8.25K
3
R72
COM
COILS
1
6
R5
C53
OP27
1
0.1
50V
/RETRACT_ARC
TCF6000
47.5K
2
X1
RELAY
J5
R115
619
5
511
R96
10
10.0K
R4
NC
511
R42
R111
COM
3
SENSE_AMPS
30.1
6
R110
X16
X16
R3
V EE
7
OUT
10.0
TCF6000
50V
R70
2.67K
4
V CC
X6
150p
R107
INPUT
-15V
10.0
COM
R23
R191
INPUT
2
OPTOCOUPLER
4.75K
100K
S
R149
10.0K
C15
3
10
J3
D20
5.11K
R34
C47
SHUNT
TRANSFER
243
R39
3.92K
3.92K
R190
243
J3
5
R94
BOARD
2N4401
SENSE_AUX
COM
8
-15V
Q3
D27
PRIMARY_POWER
NULL
R170
R91
4
COM
NULL
IGBT DRIVE
C6
1K
1
OPTOCOUPLER
4.75K
825
C74
CW
OUTPUT
R171
COM
COM
COM
R87
47.5K
PA0
1
3
J3
+15V
R189
C43
s15018-19k1
R139
34
+15V
56.2K
R138
44
26
35V
10.0K
38
PE4
2
/LD
MS-001BA
R135
PB4
PA3
10.0K
COM
C71
1.0
VREF
8
15.0K
PB3
PE0
31
3
CLK
R187
PC4
43
4
SDI
VDD
7
C29
+5.5V
/CLR
2N4401
D26
39
X15
VOUT
6
511
9
8
LM2907
50K
2
GND
5
ELECTRODE_SOLENOID
13
+5.5V
X16
-15V
Q2
R58
47.5K
PB7
I_SET
TCF6000
12
11
CW
J5
R180
R179
13
NC
X18
R29
PC3
AS
OPTOCOUPLER
4.75K
AIR SOLENOID
3.74K
47.5K
IBIAS
1.50K
PILOT_SWITCH
PE2
/PIP
10.0K
/
14
9
J3
R172
COM
Ic
4
R131
AIR_SOLENOID
PILOT_SWITCH
R184
J5
6
2
3
68.1K
AIR_SOLENOID
28
15.0K
50V
NC
R113
29
PA6
X5
R61
.0047
TACH INPUT
1.21K
30
PA5
PC7
PC5
R181
C72
COM
1.30K
1
10.0K
R160
R195
PA4
PC1
10.0K
OPTOCOUPLER
10.0K
R158
R182
R77
PRIMARY CAP
10.0K
2N4401
D25
16
12
+5.5V
Q1
825
47
35V
COM
3.74K
10
9
825
R102
COM
14
PRIMARY VOLTAGE
C30
1.0
J3
2
10K
+15V
R108
R56
6
PRESSURE SWITCH
35V
COM
COM
17
/PURGE
/PSI_OK
50V
C62
1.0
5
CONTROL_POT
/PSI_OK
0.1
COM
/OUTPUT
/SAFETY_RESET
7
GND
D13
3A
40V
C33
20V
COM
10.0K
R57
5.11K
100
J3
X10
51
E
/RESET
EXTAL
1W
2
3
R67
R136
THERMOSTAT OK
COM
TCF6000
PSI
4.75K
4.75K
R44
4.75K
10.0K
12V
C61
1.8
7
J5
5
10.0K
COM
TRIGGER
R178
COM
VRL
XTAL
7
OPEN = OVERTEMP = L
3
SG3846
DZ2
INV IN
C14
R68
SHORT = TEMP OK = H
6
10.0K
13
C13
52
R/W
/XIRQ
10.0K
10.0K
J4
VRH
/IRQ
8
1W
1
4
OUT
Vin + Vc
R99
MODB
18
12V
+5.5V
Vss
19
R17
14
R19
R164
1
X3
LM224
5.11K
332
1
2
6
12
R14
4
COM
R13
J4
+5.5V
X10
DZ1
CW
COM
R69
221K
332
THERMOSTAT(S)
TCF6000
R167
X14
12
2
1
N.I. IN
13
NOTE:
Shutdown Condition:
126 Amps = 0.35V
COM
R43
R11
R12
D12
3A
40V
267
COM
10.0K
R166
I-
COM
+15V
100V
90 Amps = 0.25V
Vss
PWM
RT
PULSE XFMR
3
J5
D11
3A
40V
R141
10
GATE DRIVE
COM
2
1
N.I. IN
330p
S-8054HN
C52
10.0K
RES
CLIM
GND
INV IN
R101
35V
X11
10p
100V
SHUT
R133
C46
C48
R137
Vdd
9
50V
Vref
3
R140
14
2.67K
Y1
+5.5V
332
.018
13
R132
C28
1.0
332
R130
22.1K
COM
R165
2
R114
130
R63
COM
+15V
33074A
GND
CT
50V
4
OUT
D10
3A
40V
0.1
5
Vin + Vc
X13
COM
4.75K
1.21K
/SAFETY_RESET
COM
2N4403
16
SYNC
Vc
V+
8
C60
+5.5V
10.0K
TRIGGER OFF = L
RESET
PUSHBUTTON
Q5
1
10.0K
TRIGGER ON = H
8.0MHz
5
C58
3
R112
R62
R55
5.11K
1.50K
R156
1
3.32K
C39
X10
R54
3
X3
2
10.0K
TCF6000
100
J2
R153
4
10.0K
3
LM224
J3
11
10.0K
OPTOCOUPLER
+5.5V
COM
D
3.74K
TRIGGER CIRCUIT
35V
R
X2
14
OUTB
V-
5
V_PWM
12
OUTA
X12
COMP
6
100V
X10
1.00M
R31
O
A
R76
C26
1.0
B
COM
221K
OPEN = TRIGGER OFF
PURGE
PUSHBUTTON
SHORT = TRIGGER ON
100p
TCF6000
R155
R152
/PURGE
R52
5
R154
10.0K
2
Vin
I+
7
C59
11
10.0K
4
+5.5V
R157
R53
5.11K
X10
TCF6000
35V
267
15
R122
10.0K
5.11K
COM
C50
4.7
COM
R134
26.7
COM
100
J2
35V
0.1
50V
COM
COM
+15V
10.0K
10.0
R196
R147
10.0
R146
10.0
R144
10.0
10.0
R145
10.0
R142
10.0
R143
10.0
R127
10.0
R128
R125
10.0
R126
10.0
R22
10.0
10.0
10.0
D18
1N4936
R129
R123
26.7
R121
D17
1N4936
C55
C54
1.0
35V
5.62K
+5.5V
125:1
R20
CURRENT
XFORMER
C32
C42
C57
1.0
10.0K
J2
9
Y
1N4936
R106
A
PRIMARY
C23
26.7
L
CONTROL_POT
R47
C21
1.0
35V
D16
1N4936
6
R120
R45
P
R49
J2
8
S
MIN
100K
I
10K
CUTTING
CONTROL
POT
J4
3
D15
C56
.15
100V
TCF6000
100K
4.75K
R124
X10
J2
6
D
26.7
LOCAL
...
s15018-19k1
G
SETPOINT
+15V
3
CUTTING CURRENT
MAX
+15V
Vct = 0.0057 Ip
+15V
3
1
2
5
4
8
NOTES :
N.A.
J1
J2 J4 J4 J5 J5
SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE
WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE
NUMBER.
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.
G3327
9-4-98D
PRO CUT 55
G-8
G-8
ELECTRICAL DIAGRAMS
Control P.C. Board Assembly (G3328-1)
ITEM
PART NO.
REQ'D
))
C1
)
1
)
C2,C8,C10,C13,C14,C17,C20
S13490-92
)
31
S16668-5
DESCRIPTION
3300/50
.022/50
C23,C24,C29,C31,C34,C35
C36,C37,C39,C40,C41,C47
C53,C55,C58,C63,C64,C65
C66,C68,C69,C73,C74,C75
))
C3
))
C4,C18
C5
))
C6
))
))
C7,C9
)
C15,C16,C32,C33,C42
))
C19,C25,C50
1
)
S13490-121
2
)
S13490-63
.47/50
1
)
S13490-71
100/50
1
)
T11577-52
.0047 or .005/1400
2
)
S13490-93
27/35
5
)
S16668-11
.1/50
3
)
C21,C26,C28,C30,C54,C57
)
S13490-25
)
8
S13490-42
1000/35
4.7/35
1.0/35
C62,C71
))
C22,C43,C44
))
2
)
S16668-13
))
1
)
S16668-8
))
1
)
S13490-108
C59
))
1
)
S16668-3
C60
))
1
)
S13490-126
C61
))
1
)
S13490-19
1.8/20
C72
))
1
)
S16668-10
4700pF/50
C34
R137
R108
R31
C25
S18248-10
S18248-16
S18248-6
HEADER
R61
J5
))
1
)
S18248-8
HEADER
3
RED LED
C54
C55
R133
C20
R132
T12704-68
2N4401
)
T12704-80
HEXFET TRANS. (SS)
Q5
))
1
R1
))
1
))
R138
)
T12704-69
HEXFET TRANS. (SS)
)
T13165-16
1.0 OHM, 5W RESISTOR
3
)
S19400-2671
2.67K 1/4W
9
)
S19400-2430
243 1/4W
R38,R39
R140
C59
)
R3,R30,R32,R33,R34,R36,R37
C60
R131
C58
R129
T13657-2
)
1
))
R2,R46,R132
R130
C61
C62
R134
C48
R112
R168
R114
)
3
))
Q1,Q2,Q3
X12
R135
R139
R141
R900
R55
)
HEADER
Q4
LED1,LED2,LED3
C19
HEADER
R4
))
1
)
S19400-30R1
30.1 1/4W
R5
))
1
)
S19400-6190
619 1/4W
R6
))
1
)
S19400-8251
8.25K 1/4W
R7
))
R8
))
R10,R42,R95,R96
)
R11,R12,R13,R14
)
)
R17,R26,R27,R49,R51,R59
D12
)
1
))
R9,R88,R103
S19400-3921
3.92K 1/4W
1
)
S19400-2001
2.0K 1/4W
3
)
S19400-1001
1K 1/4W
4
)
4
)
)
35
S19400-5110
511 1/4W
S19400-3320
332 1/4W
S19400-1002
10K 1/4W
X14
R61,R62,R63,R68,R69,R81
R84,R93,R94,R104,R106,R108
R134,R138,R139,R152
R164,R165,R166,R178
R179,R180,R181,R182
))
R18
)
R19,R47,R53,R55,R57,R85
D10
D11
C42
1
)
S24073-1
8
)
S19400-5111
5.11K 1/4W
S19400-10R0
10 1/4W
)
S19400-1822
18.2K 1/4W
)
S19400-2210
221 1/4W
S19400-3321
3.32K 1/4W
)
S19400-8250
825 1/4W
)
S19400-1004
1M 1/4W
S19400-7681
7.68K 1/4W
10K,1/2W,TRIMMER
R149,R157
)
X13
R20,R22,R110,R111,R124,R125
)
16
R126,R127,R128,R142,R143
C21
R45
R52
R54
R118
R144,R145,R146,R147.R901
R117
C56
R120
R121
1N4936
)
R47
C40
R159
R115
D18
D16
R128
R127
R126
D17
R122
R123
D15
S18248-4
)
C23
R49
R116
R147
C57
R145
R146
R144
R143
R142
R22
R20
R125
R124
R21
R82
R152
R154
R155
C39
R153
C13
R76
R13
R164
)
)
DZ1
R83
C10
R156
R157
R11
R14
C36
C37
R32
R33
C47
R38
R39
C35
D26
R171
1
R153,R154,R156,R158,R160
Q4
R12
R36
R27
R30
C16
R94
R34
C15
R37
R29
R67
R170
Q2
R58
D25
R87
R102
R100
R99
Q1
R101
D27
R172
R91
Q3
D1
))
1
C50
R17
X3
1N4742A
HEADER
J1
1N5822 SCHOTTKY BARRIER DIODE
1
R19
D2
TP2
R901
C8
C69
C68
R26
C2
R93
R167
C9
D8
D7
C7
D3
TP1
D4
R165
T12702-19
1
R166
X4
T12705-34
)
))
C1
X6
)
2
))
C33
C28
R51
5
))
R183
D13
D14
R113
R63
R109
C18
T12705-37
J4
DZ2
R119
C26
R18
R53
R77
R73
))
)
J3
C64
X2
R88
R40
R28
R46
R72
C43
R70
C53
R42
X9
R96
R35
C66
D21
C17
R98
C63
C65
R177
R103
R1
R24
X1
R62
R180
R23
R107
D22
R104
D19
R59
C31
1N4004
4
J2
R184
R106
R85
R84
R179
R149
C41
C4
D23
R80
R81
C29
R97
R89
R169
C45
R48
.018/50V
C46
X16
C44
T12199-1
.15/100
100pF/100
R136
Q5
R78
C22
R79
D5
LED1
LED3
R178
R43
R44
R69
R68
C24
R56
R57
C30
R160
R182
X5
X7
C5
R175
R158
D28
R95
D9
R3
R2
C3
X10
)
D15,D16,D17,D18,D21
Y1
)
16
)
DZ1,DZ2
C14
X15
R181
C75
C74
R174
C72
C71
X18
R173
R176
R9
R10
R7
R8
R6
R4
R5
D6
X8
)
10pF/100
330pF/100
D26,D27
D10,D11,D12,D13
C52
X11
150pF/100
2700pF/50
C56
D14,D20,D22,D23,D25
C73
LED2
S16668-4
C48
D1,D2,D3,D4,D5,D6,D7,D8,D9
G3328-1
S16668-9
)
1
C46,C52
PRO-CUT 50 CONTROL
)
3
))
C45
D20
R111
R110
C6
C32
R21,R23
))
R24,R35
))
2
2
)
R28,R112,R115,R116,R117
7
)
R118,R119
))
R29,R91,R102
J1
J3
J4
J2
J5
3
))
R31
1
))
R40,R73,R107
3
)
R43,R44,R45,R136,R137,R170
8
)
)
S19400-4751
4.75K
R171,R172
)
R48,R67,R70,R87,R101
))
R52,R54,R56
)
R58,R76,R99,R100
))
R72, R900
))
R77
))
R82,R175,R177
)
R78,R113,R114,R159
)
)
R79,R83,R155,R167
))
R80,R89
5
)
S19400-4752
47.5K 1/4W
3
)
S19400-1000
100 1/4W
4
)
S19400-3741
3.74K 1/4W
2
)
S19400-1501
1.5K 1/4W
1
)
S19400-2211
2.21K 1/4W
3
)
S19400-1301
1.3K 1/4W
4
)
S19400-1211
1.21K 1/4W
4
)
S19400-2213
221K 1/4W
2
)
S19400-1003
100K 1/4W
R98
))
1
)
S19400-2431
2.43K 1/4W
R97
))
1
)
S19400-8252
82.5K 1/4W
1
)
S19400-6811
6.81K 1/4W
4
)
S19400-26R7
26.7 1/4W
1
)
S19400-2212
22.1K 1/4W
))
R109
)
R120,R121,R122,R123
))
R130
R131,R174
))
2
)
S19400-6812
68.1K 1/4W
R133,R173
))
2
)
S19400-2672
26.7K 1/4W
R140,R141
))
2
)
S19400-2670
267 1/4W
))
R135,R183
))
R176
))
R129,R184
))
TP1,TP2
X1,X2
X3
X4,X6
))
))
))
2
)
S19400-1502
15K 1/4W
1
)
S19400-4750
475 1/4W
2
)
S19400-5621
2
)
T13640-15
2
)
S15128-16
1
)
S15128-4
2
)
S15128-13
)
1
X7
))
1
)
S18647
X8
))
1
)
S18395-13
X9
))
1
)
S15128-12
2
)
S15018-18
X5
))
X10,X16
))
X11
X12
))
)
1
1
))
S24085-1
)
M15102-3
M15458-2
5.62K 1/4W
15J
LINEAR INTEGRATED CIRCUIT
LM224 OP-AMP
PRECISION OP AMP IC
ROM ASSEMBLY
REGULATOR ASBLY
5V REG. ASBLY
VOLTAGE REGULATOR
IC,ARRAY,CLAMPING
RESET I.C. UNDERVOLT. SENSING CIR. (SS)
PWM CONTROLLER I.C. (SS)
2
)
S15018-19
IC, DRIVER, FET, 6A
X15
))
1
)
M15105-8
CMOS,CONVERTER,D/A,SERIAL,10-BIT (SS)
X18
))
1
)
M13552-2
FREQ. TO VOLTAGE CONVERTER
Y1
))
1
)
S16665-5
8.0 MHZ
X13,X14
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.
G3328-1
11-21-97L
PRO CUT 55
G-9
G-9
ELECTRICAL DIAGRAMS
Control P.C. Board Assembly (G3328-2)
ITEM
PRO-CUT 50 CONTROL
C29
C74
R137
R108
R31
R178
R43
R68
PART NO.
DESCRIPTION
C52
X11
R173
X18
R44
C75
R95
R176
LED2
X8
C73
R9
R10
R7
R8
R6
R4
R5
D6
C71
R69
G3328-2
C72
REQ'D
Y1
X15
R187
C14
C20
J3
J4
J2
C21
R45
R52
R54
R118
R117
C56
R120
R121
R122
D17
D15
R123
R125
R124
R21
R82
R152
R154
C39
R153
R155
R76
R13
C13
R164
R14
C36
C37
R32
R33
C47
R39
R38
C35
R172
D27
R171
Q3
D25
D26
Q2
R170
R138
R140
X13
R47
C40
R159
R115
D18
D16
R83
R128
R127
C10
R166
R167
R165
R156
R157
R11
R12
R36
R27
R30
C16
R94
R34
C15
R37
R91
R100
R101
R58
R67
R29
R99
R87
R102
Q1
X3
C42
D10
D11
C9
Q4
D2
C59
DZ1
R17
TP2
D1
R134
C50
R19
J1
R129
X14
C23
R49
R116
R147
R145
R22
R146
R196
R20
R126
D12
D13
C28
C26
R109
R142
R143
R144
R192
R193
X4
C61
C62
C48
R112
R195
R141
R135
R114
R113
R55
R53
R77
R139
DZ4
R183
R184
R149
R180
R179
R106
R85
R84
C18
R194
C69
C8
C2
C68
DZ2
C33
D14
R26
R93
C58
R73
R18
D8
D7
TP1
X12
C64
X2
C57
R40
R46
R28
R72
C43
R70
R23
C17
C1
X6
R104
R88
C66
C63
C65
R103
C53
X9
X1
R35
R191
R190
R189
R42
C76
C7
D21
C31
R24
R188
R96
R1
R177
R98
C45
R48
R107
LED3
C41
C4
D23
R80
R81
R97
R89
X16
R78
C22
R79
R182
C5
D5
C19
C55
C54
C60
C34
R63
C44
D3
R133
R62
Q5
LED1
D4
R61
C25
C24
R57
R174
C30
X5
R131
C3
R158
X7
R2
R132
R136
X10
R130
R175
R3
R56
D9
R160
R181
C46
D20
R111
R110
C6
C32
J5
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.
G3328-2
9-4-98D
PRO CUT 55
G-10
G-10
ELECTRICAL DIAGRAMS
Output P.C. Board Assembly (G3326-1)
xxxxxxxx
xxxxxxxx
xx
xxxxxxx
xxxxxxxx
xxxxxxxx
xxxxxxx
xxx
xxxxxxxx
xxxxxxxxxx
xxxxxxxxx
xxxxxxxxxx
xx
xxxxxxx
G3326-1
PRO-CUT 55 OUTPUT
xxx
xxxx
xxxxxxxxx
xxxx
ITEM
NOTE:
REQ'D
PART NO
IDENTIFICATION
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.
G3326-1
10-31-97E
G-11
G-11
ELECTRICAL DIAGRAMS
Output P.C. Board Assembly (G3326-2)
xxxxxxx
xxxxxxx
xxxxxxxxxx
xxxxxxx
xxxxxxxxxx
xxxxxxxxxx
xxxxxxxxxx
xxxxxxxxxx
G3326-2
xxx
xxxxxxxxxx
NOTE:
REQ'D
PART NO
PRO-CUT 55 OUTPUT
xxxx
xxx
xxxxxxx
xxxxxxxxxx
xxxxxxx
xxxxxxxxxx
xxxxxxxxx
xxxxxxxxxx
ITEM
IDENTIFICATION
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.
G3326-2
5-29-98D
G-12
G-12
ELECTRICAL DIAGRAMS
Power P.C. Board Assembly (G3172-1)
REQ'D
ITEM
C1,C5,C8,C11
)))
4
)
S16668-6
C2,C6,C9,C12
)))
4
)
S20500-4
3
)
S16668-5
1
)
S13490-93
)
S16668-9
)))
C3,C4,C14
)))
C7
C10
)))
1
C13
)))
1
)
S13490-130
CR1
)))
1
)
S14293-18
D7
))
D1,D2,D3,D4,D5,D6,D7,D12
J10
)
10
IDENTIFICATION
PART NO
))
4700pF/50
))
.0047/1000V
))
.022/50
))
27/35
))
150pF/100
))
))
T12199-1
))
))
.27/50
DPST RELAY
1N4004
D13,D14
R61
)))
D8,D9,D10,D11
C10
1RC
4
)
T12705-44
4
)
T12702-40
))
1N4735
9
)
T12702-29
))
1N4744A
DIODE 1000V/1A
1T
))
DZ1,DZ5,DZ9,DZ12
))
DZ2,DZ3,DZ6,DZ7,DZ8,DZ10
OCI2
DZ11,DZ13,DZ14
B209
R60
D12
R57
D11
)))
1
)
T12704-75
))
FET (SS)
)))
1
)
T12704-73
))
IC PKG MOSFET (SS)
R77
DZ8
R71
R18
C4
R19
R17
OCI1
R1
DZ1
B207
B206
DZ4
Q1
DZ5
R20
DZ6
R78
R33
R90
D6
R85
R95
DZ10
R67
C8
R88
R45
))
)))
)))
)
S19400-10R0
))
10 1/4W
17
)
S19400-1001
))
1K 1/4W
R92
R44
R91
R43
R42
2A
1A
R96
R82
8
)
T14648-21
3
)
T14649-4
))
2.7 OHM 5W
10
)
))
100 10W
S19400-1503
))
150K 1/4W
1
)
S19400-1000
))
100 1/4W
2
)
S19400-1821
))
1.82K 1/4W
))
267K 1/4W
R19
)))
1
)
S19400-2673
R28
)))
1
)
T10812-41
))
10K 1/2W TRIMMER
8
)
T14648-12
))
1500 OHM 5 WATT RESISTOR
))
R73,R74
3
)
S19400-3321
))
3.32K 1/4W
R36,R52,R89,R90
)))
))
4
)
S19400-6191
))
6.19K 1/4W
R37,R55,R91,R92
))
4
)
S19400-1502
))
15K 1/4W
2
)
S19400-1652
))
16.5K 1/4W
4
)
S19400-3323
))
332K 1/4W
1
)
S19400-1372
))
13.7K 1/4W
4
)
S19400-1002
))
10K 1/4W
R33,R38,R58
)))
))
R40,R56,R84,R87
R54
B204
C9
R84
R97
C13
12
R50,R51,R83,R86
R39,R53
D10
Q2
C6
G3172-1
B202
R38
R47
R87
R89
PRO-CUT POWER
R48
R6
R83
R94
DZ11
R24
R93
DZ9
R23
D14
X3
R21
R22
D13
C14
R41
R12
B203
C5
R98
))
)))
R29,R30,R31,R32,R71,R72
R54
R79
))
))
R13,R14,R15,R16,R34,R35
R18,R77
R28
OPTO ISOLATOR
Q2
R17
DZ14
R86
))
Q1
R10,R11,R12
C11
DZ13
R26
S15000-22
HEADER
R69
R63
DZ7
D9
)
)))
R7,R8,R26,R27,R47,R48,R68
R72
R16
D8
R66
R46
B208
2
))
R63, R64,R65,R66
R81
R64
R65
DZ3
S20351-6
1N4742A
R24,R42,R43,R44,R45,R60
R62
R76
R80
DZ2
)
R2,R3,R4,R5,R21,R22,R23
DZ12
R75
C1
1
R1,R6,R20,R25,R41,R46,R62
X1
R4
R2
)))
))
T12702-19
R67,R79,R80,R81,R82
R34
R3
)
R68
R37
R74
R35
R73
D2
C7
R5
R27
C12
R11
R36
R39
R15
C2
R25
B201
D5
R56
R14
R32
B205
R50
D3
R53
R7
J10
OCI1,OCI2
R51
R52
R55
R8
1
R40
D4
R30
R29
)))
R69
X2
D1
R13
R31
C3
R59
R58
R10
DZ4
)))
))
R57,R59,R85,R88
R61
)))
1
)
S19400-2213
))
221K 1/4W
R75
)))
1
)
S19400-5620
))
562 1/4W
2
)
S19400-2801
))
2.8K 1/4W
)))
R76,R98
R78
)))
1
)
S19400-2001
))
2.0K 1/4W
R93
)))
1
)
S19400-4751
))
4.75K
R94
)))
1
)
S19400-4752
))
47.5K 1/4W
2
)
S19400-2211
))
2.21K 1/4W
1
)
T12300-79
))
1 WATT 1 OHM 1% RESISTOR
))
TRANSFORMER
))
VOLTAGE REF.
)))
R95,R96
R97
)))
T1
)))
1
)
S13000-46
X1
)))
1
)
S15128-10
X2
)))
1
)
S15128-4
X3
)))
1
)
S15128-18
))
))
LM224 OP-AMP
QUAD-OP AMP
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.
G3172-1
10-31-97E
PRO CUT 55
G-13
G-13
ELECTRICAL DIAGRAMS
Power P.C. Board Assembly (G3172-2)
ITEM
REQ'D
PART NO
IDENTIFICATION
PRO-CUT POWER
G3172-2
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.
G3172-2
5-29-98H
PRO CUT 55