SVM140-A View Safety Info July, 2005 ™ PRO-CUT 55 For use with machine code numbers Below 11000 Return to Master TOC View Safety Info View Safety Info Safety Depends on You Return to Master TOC Return to Master TOC RETURN TO MAIN MENU 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.
Return to Master TOC i WARNING PLASMA CUTTING or GOUGING 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.
Return to Master TOC ii ii SAFETY 4.g. Sparks and spatter are thrown from the plasma arc. Wear safety glasses, ear protection and oil free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs when cutting or gouging out of position or in confined places. Always wear safety glasses with side shields when in a cutting or gouging area. 4.h. Connect the work cable to the work as close to the cutting or gouging area as practical.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC iii NOTES PRO-CUT 55 iii
iv iv MASTER TABLE OF CONTENTS FOR ALL SECTIONS RETURN TO MAIN MENU Page Safety .................................................................................................................................................i-iii Installation .............................................................................................................................Section A Operation.........................................................................................................................
Return to Master TOC Section A-1 TABLE OF CONTENTS - INSTALLATION SECTION - Section A-1 Installation Technical Specifications .............................................................................................................A-2 Safety Precautions......................................................................................................................A-4 Select Suitable Location.........................................................................................................
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC 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 Return to
Return to Master TOC Return to Section TOC 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) (6 CFM) 80 to 150 PSI (5.4 Bar. to 10.2 Bar.) RECOMMENDED INPUT WIRE AND FUSE SIZES Return to Master TOC Return to Section TOC For all plasma cutting applications based on U.S.
Return to Master TOC Return to Section TOC 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.
Return to Master TOC Return to Section TOC A-5 INSTALLATION INPUT CONNECTIONS A-5 GROUND CONNECTION WARNING ELECTRIC SHOCK can kill. • Have a qualified electrician install and service this equipment. • Turn the input power off at the fuse box before working on this equipment. The frame of the Pro-Cut 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.
Return to Master TOC Return to Section TOC A-6 A-6 INSTALLATION RECONNECT PROCEDURE FIGURE A.2 – RECONNECTION DIAGRAM When received directly from the factory, the machines are internally connected for 230 VAC. Reconnection will be necessary if a higher input voltage is used. To reconnect the Pro-Cut to 460 VAC or to connect back to 230 VAC, follow the directions as outlined below. Follow this procedure ONLY while the Pro-Cut is disconnected from the input power.
Return to Master TOC Return to Section TOC 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.
Return to Master TOC Return to Section TOC A-8 A-8 INSTALLATION FIGURE A.4 - TORCH CONNECTION AT CASE FRONT OUTPUT CONNECTIONS 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.
Return to Master TOC Section B-1 Section B-1 TABLE OF CONTENTS - OPERATION SECTION Operation...............................................................................................................................Section B Safety Instructions ......................................................................................................................B-2 General Description ....................................................................................................................
Return to Master TOC Return to Section TOC B-2 OPERATION OPERATING INSTRUCTIONS Read and understand this entire section of operating instructions before operating the machine. SAFETY INSTRUCTIONS WARNING Return to Master TOC Return to Section TOC 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.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC 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.
Return to Master TOC Return to Section TOC 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).
Return to Master TOC Return to Section TOC B-5 OPERATION 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.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC 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.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC B-7 OPERATION PREHEAT TEMPERATURE FOR PLASMA CUTTING WARNING ELECTRIC SHOCK can kill. • Turn off machine at the disconnect switch on the front of the machine before tightening, cleaning or replacing consumables. - Check the conditions of the inside of the nozzle. If debris has collected, rub the electrode on the inside bottom of the nozzle to remove any oxide layer that may have built up.
Return to Master TOC OPERATION THICK SECTIONS OF METAL Torch Standoff Machine Output Setting 1/8" thru 3/16" Standoff Output Setting Mid. thru Max. Range Return to Master TOC Output set above mid-range. Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC B-8 • 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.
Section C-1 TABLE OF CONTENTS - ACCESSORIES Accessories...........................................................................................................................Section C Options/Accessories...................................................................................................................
Return to Master TOC Return to Section TOC C-2 ACCESSORIES ALWAYS USE GENUINE LINCOLN ELECTRIC ELECTRODES AND VORTECH™ NOZZLES 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. • Only Genuine Lincoln Electric consumables yield the best cutting performance for the Pro-Cut 55.
Section D-1 TABLE OF CONTENTS -MAINTENANCEMaintenance .........................................................................................................................Section D Safety Precautions......................................................................................................................D-2 Input Filter Capacitor Discharge Procedure ...............................................................................D-2 Routine Maintenance.........................................
Return to Master TOC Return to Section TOC 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.
Return to Master TOC Return to Section TOC 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. Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC ELECTRIC SHOCK can kill.
Return to Master TOC Return to Section TOC D-4 D-4 Maintenance FIGURE D.2 – MAJOR COMPONENT LOCATIONS 1. Case Front 2. Case Back 3. Primary Power Board 4. Output Power Board Assembly 5. Control Board 6. Case Wraparound 6 7. Machine Base 8. Auxiliary Transformer Return to Master TOC Return to Section TOC 9.
Return to Master TOC 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 THEORY OF OPERATION Return to Master TOC Return to Section TOC E-2 FIGURE E.
E-3 THEORY OF OPERATION Return to Master TOC Return to Section TOC E-3 FIGURE E.
E-4 THEORY OF OPERATION Return to Master TOC Return to Section TOC E-4 FIGURE E.
Return to Master TOC Return to Section TOC E-5 E-5 THEORY OF OPERATION FIGURE E.
E-6 THEORY OF OPERATION Return to Master TOC Return to Section TOC E-6 FIGURE E.
Return to Master TOC Return to Section TOC E-7 THEORY OF OPERATION 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.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 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.
Return to Master TOC Return to Section TOC 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.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC E-10 NOTES PRO-CUT 55 E-10
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.........................................................................
Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC 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.
TROUBLESHOOTING & REPAIR WARNING ELECTRIC SHOCK can kill. • Have an electrician install and service this equipment. Turn the input power OFF at the fuse box before working on equipment. Do not touch electrically hot parts. Return to Master TOC Return to Section TOC CAUTION Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections.
Return to Master TOC 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.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-5 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) Return to Master TOC Return to Section TOC All the status lights begin to blink within 5 seconds of power up. The machine powers up properly, but there is no response when the gun trigger is pulled. Only the power LED is lit. 1.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC 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.
Return to Master TOC Return to Section TOC F-7 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) Return to Master TOC 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.
Return to Master TOC Return to Section TOC F-8 TROUBLESHOOTING & REPAIR Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) RECOMMENDED COURSE OF ACTION Return to Master TOC POSSIBLE AREAS OF MISADJUSTMENT(S) LED FUNCTION PROBLEMS The Air Low LED is lit. Return to Section TOC F-8 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.
Return to Master TOC Return to Section TOC F-9 Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) RECOMMENDED COURSE OF ACTION Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC POSSIBLE AREAS OF MISADJUSTMENT(S) LED FUNCTION PROBLEMS The Thermal LED is lit. Return to Section TOC TROUBLESHOOTING & REPAIR F-9 1. One of the machine’s thermostats has tripped.
PRO-CUT 55 Y Will arc transfer to work piece? Y Is pilot arc smooth and continuous? N N N After 2 seconds of preflow, does pilot arc start? Y N N Does preflow gas flow from torch? Pull gun trigger and hold Press PURGE button, set pressure to 70psi, then release. If no air flow from torch, perform Gas Solenoid Test.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-11 NOTES PRO-CUT 55 F-11
Return to Master TOC Return to Section TOC F-12 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.
Return to Master TOC Return to Section TOC F-13 TROUBLESHOOTING & REPAIR INPUT FILTER CAPACITOR DISCHARGE PROCEDURE (continued) WARNING ELECTRIC SHOCK can kill. • Have an electrician install and service this equipment. • Turn the input power off at the fuse box before working on equipment. Return to Master TOC Return to Section TOC Return to Master TOC 5. Locate the four capacitor terminals (large hex head cap screws) shown in Figure F.1.
Return to Master TOC Return to Section TOC F-14 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.
Return to Master TOC Return to Section TOC F-15 TROUBLESHOOTING & REPAIR INPUT RECTIFIER TEST (continued) TEST PROCEDURE 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. 3. Locate the input rectifier (D1) and lead locations.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-16 TROUBLESHOOTING & REPAIR INPUT RECTIFIER TEST (continued) TABLE F.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-17 NOTES PRO-CUT 55 F-17
Return to Master TOC 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.
Return to Master TOC Return to Section TOC F-19 F-19 TROUBLESHOOTING & REPAIR PRIMARY POWER BOARD RESISTANCE TEST AND CAPACITOR VOLTAGE TEST (continued) FIGURE F.
Return to Master TOC Return to Section TOC F-20 TROUBLESHOOTING & REPAIR PRIMARY POWER BOARD RESISTANCE TEST AND CAPACITOR VOLTAGE TEST (continued) TABLE F.
Return to Master TOC Return to Section TOC F-21 TROUBLESHOOTING & REPAIR PRIMARY POWER BOARD RESISTANCE TEST AND CAPACITOR VOLTAGE TEST (continued) CAPACITOR VOLTAGE TEST This test will help the technician to determine if the input filter capacitors are being charged equally to the correct voltage levels.
Return to Master TOC Return to Section TOC F-22 TROUBLESHOOTING & REPAIR PRIMARY POWER BOARD RESISTANCE TEST AND CAPACITOR VOLTAGE TEST (continued) 6. Check for the appropriate voltages outlined in Table F.3. NOTE: Voltages may vary with the input line voltage. Return to Master TOC 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. Return to Section TOC F-22 7.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-23 NOTES PRO-CUT 55 F-23
Return to Master TOC 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.
Return to Master TOC Return to Section TOC F-25 F-25 TROUBLESHOOTING & REPAIR OUTPUT POWER BOARD RESISTANCE TEST (continued) FIGURE F.4 – OUTPUT POWER BOARD LEAD LOCATIONS X4 (B11) B21 Point D30 Test (G3326-2,3) G3326 - [ ] PRO-CUT 55 OUTPIUT J33 x40 B1 B2 x20 R5 Test Point (G3326-1) (only) R5 Return to Master TOC Return to Section TOC X2 (B12) J31 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC J32 TEST PROCEDURE 1.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-26 TROUBLESHOOTING & REPAIR OUTPUT POWER BOARD RESISTANCE TEST (continued) TABLE F.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-27 NOTES PRO-CUT 55 F-27
Return to Master TOC 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.
F-29 TROUBLESHOOTING & REPAIR Return to Master TOC Return to Section TOC F-29 TORCH CONTINUITY AND SOLENOID TEST (continued) FIGURE F.5 - TORCH CONNECTOR - MACHINE END Electrode is insulated from Brass Body White Pair Black Pair Electrode Lead BO DY Connector 7 Not used inside power source Return to Master TOC Return to Section TOC outside 9 6 Vent Tube Return to Master TOC Return to Master TOC flex tubes center th / air Pilot pa 4 tube crimp 1 Air Hose 2 g fittin Red Leads N.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-30 F-30 TROUBLESHOOTING & REPAIR TORCH CONTINUITY AND SOLENOID TEST (continued) 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.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-31 NOTES PRO-CUT 55 F-31
Return to Master TOC 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.
Return to Master TOC Return to Section TOC F-33 TROUBLESHOOTING & REPAIR F-33 AIR/GAS SOLENOID TEST (continued) FIGURE F.6 – AIR SOLENOID Return to Master TOC Return to Section TOC 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.
Return to Master TOC 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.
Return to Master TOC Return to Section TOC F-35 F-35 TROUBLESHOOTING & REPAIR (T2) AUXILIARY TRANSFORMER TEST (continued) FIGURE F.8 – T2 AUXILIARY TRANSFORMER 5 4 9 8 2 6 PLUG J21 Return to Master TOC Return to Section TOC PLUG J21 (H5) 6 (H2) 4 PLUG J22 3 (H4) 2 (H3) 1 (H1) PLUG J22 (6 Cavity) T2 AUXILIARY TRANSFORMER (H5) 8 (H4) 7 (H2) 5 2 (H3) 1 (H1) PLUG J22 (8 Cavity) PROCEDURE Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 1.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-36 TROUBLESHOOTING & REPAIR (T2) AUXILIARY TRANSFORMER TEST (continued) TABLE F.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-37 NOTES PRO-CUT 55 F-37
Return to Master TOC 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.
F-39 TROUBLESHOOTING & REPAIR Return to Master TOC Return to Section TOC F-39 TRIGGER CIRCUIT TEST (continued) FIGURE F.9 – SIMPLIFIED TRIGGER CIRCUIT DIAGRAM (Later Versions) OUTPUT BOARD CONTROL BOARD +17VDC +15VDC TORCH RECEPTACLE 9 #4 1J31 (1J38) #2 2J31 (7J38) P R O C E S S O R TRIGGER SWITCH Return to Master TOC Return to Section TOC IN TORCH HANDLE 1 3J32 (3J35) 14J32 (6J35) D25 AUX COM PROCEDURE 1. Remove input power to the Pro-Cut 55 machine.
Return to Master TOC Return to Section TOC F-40 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.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-41 F-41 TROUBLESHOOTING & REPAIR TRIGGER CIRCUIT TEST (continued) FIGURE F.
Return to Master TOC Return to Section TOC F-42 TROUBLESHOOTING & REPAIR TRIGGER CIRCUIT TEST (continued) FIGURE F.11 - CONTROL BOARD LEDs PRO-CUT 55 CONTROL G3328 LED2 LED1 Return to Master TOC Return to Section TOC LED3 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC CONTROL BOARD LED DEFINITIONS LED1: (Red) This light indicates that 18 VAC is being supplied to the control board from the auxiliary transformer.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-43 NOTES PRO-CUT 55 F-43
Return to Master TOC Return to Section TOC F-44 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.
Return to Master TOC Return to Section TOC F-45 F-45 TROUBLESHOOTING & REPAIR LOW VOLTAGE CIRCUIT TEST (continued) FIGURE F.
Return to Master TOC Return to Section TOC F-46 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.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-47 TROUBLESHOOTING & REPAIR F-47 LOW VOLTAGE CIRCUIT TEST (continued) FIGURE F.
Return to Master TOC Return to Section TOC F-48 TROUBLESHOOTING & REPAIR F-48 LOW VOLTAGE CIRCUIT TEST (continued) FIGURE F.14 – CONTROL BOARD LEDs PRO-CUT 55 CONTROL G3328 LED2 LED1 Return to Master TOC Return to Section TOC LED3 Return to Master TOC Return to Section TOC CONTROL BOARD LED DEFINITIONS LED1: (Red) This light indicates that 18 VAC is being supplied to the control board from the auxiliary transformer.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-49 NOTES PRO-CUT 55 F-49
Return to Master TOC 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.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-51 TROUBLESHOOTING & REPAIR 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. Return to Master TOC Return to Master TOC Return to Section TOC 2. Remove the wraparound cover and perform the Input Filter Capacitor Discharge Procedure detailed earlier in this section. Return to Section TOC F-51 3.
Return to Master TOC Return to Section TOC F-52 TROUBLESHOOTING & REPAIR F-52 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. Return to Master TOC Return to Section TOC FIGURE F.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-53 NOTES PRO-CUT 55 F-53
Return to Master TOC Return to Section TOC F-54 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.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-55 TROUBLESHOOTING & REPAIR F-55 DISPLAY BOARD REMOVAL & REPLACEMENT (continued) FIGURE F.19 - CASE FRONT SCREW REMOVAL 4 SCREWS PROCEDURE Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 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.
Return to Master TOC Return to Section TOC F-56 TROUBLESHOOTING & REPAIR F-56 DISPLAY BOARD REMOVAL & REPLACEMENT (continued) FIGURE F.20 – DISPLAY BOARD REMOVAL DISPLAY BOARD Return to Master TOC Return to Section TOC CASE FRONT Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC 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.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-57 NOTES PRO-CUT 55 F-57
Return to Master TOC Return to Section TOC F-58 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.
Return to Master TOC Return to Section TOC F-59 TROUBLESHOOTING & REPAIR F-59 OUTPUT POWER BOARD REMOVAL & REPLACEMENT (continued) FIGURE F.21 – OUTPUT POWER BOARD REMOVAL Return to Master TOC Return to Section TOC OUTPUT POWER BOARD Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC PROCEDURE 1. Remove input power to the Pro-Cut 55 machine. 2.
Return to Master TOC Return to Section TOC F-60 TROUBLESHOOTING & REPAIR F-60 OUTPUT POWER BOARD REMOVAL & REPLACEMENT (continued) FIGURE F.22 – OUTPUT BOARD LEAD LOCATIONS x4 G3326 - [1] PRO-CUT 55 OUTPIUT J33 Return to Master TOC Return to Section TOC x40 B1 B2 x2 x20 B21 J31 J32 Return to Master TOC Return to Section TOC 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.
Return to Master TOC Return to Section TOC F-61 TROUBLESHOOTING & REPAIR OUTPUT POWER BOARD REMOVAL & REPLACEMENT (continued) 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.
Return to Master TOC Return to Section TOC F-62 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.
Return to Master TOC TROUBLESHOOTING & REPAIR F-63 PRIMARY POWER BOARD AND FILTER CAPACITOR REMOVAL AND REPLACEMENT (continued) FIGURE F.23 – PRIMARY POWER BOARD REMOVAL PRIMARY POWER BOARD WITH INPUT FILTER CAPACITORS Return to Master TOC Return to Section TOC Return to Section TOC F-63 REMOVAL PROCEDURE Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 1. Remove input power from the Pro-Cut 55 machine. 2.
F-64 TROUBLESHOOTING & REPAIR Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-64 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) Return to Master TOC Return to Section TOC 3/8" MOUNTING INSULATOR (2) MOUNTING SCREW (2) Return to Master TOC Return to Section TOC 7.
Return to Master TOC Return to Section TOC F-65 TROUBLESHOOTING & REPAIR PRIMARY POWER BOARD AND FILTER CAPACITOR REMOVAL AND REPLACEMENT (continued) CAPACITOR REMOVAL 1. Using the 3/8” wrench, remove the four screws holding the heat sink 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. Return to Master TOC Return to Section TOC 3.
Return to Master TOC 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.
Return to Master TOC Return to Section TOC F-67 TROUBLESHOOTING & REPAIR 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.
Return to Master TOC Return to Section TOC F-68 TROUBLESHOOTING & REPAIR INPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued) 7. Carefully remove the input rectifier bridge. 8. When installing a new input rectifier apply a thin coating of Penetrox A-13 Heat Sink Compound (Lincoln E2529) to the mating surfaces. Torque the mounting cap screws and nuts to 44 in-lbs. Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC 9.
Return to Master TOC Return to Section TOC F-69 F-69 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.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-70 NOTES PRO-CUT 55 F-70
Return to Master TOC 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) ........
WIRING DIAGRAM PRO-CUT 55 RIGHT SIDE OF MACHINE + 404 + T3 CURRENT TRANSFORMER Y 205 Y 207A -O FR S + C2- J31 1,2 TRIGGER 3 NOZZLE 4 ELECTRODE 5,6 AIR SOL 7,8 ELEC SOL 10 WORK Return to Master TOC J32 8 AIR SOL 2 ELEC SOL 3 TRIGGER 13 IGBT 14 GND J30 1,4=24V OUTPUT 12V 1 2 3 4 10 5 6 7 8 9 4 1 51 54 G 5 2 56 6 3 53 L1 CHOKE S E FR -IN X2 T FR -O U U T S T BK -O U BK -IN 365 X20 Y xxxxxxx Return to Master TOC Y 404 401 18V W R 306 W R 312 303 344 302 310 360 309 200208V
Return to Master TOC ELECTRICAL DIAGRAMS G-3 SCHEMATIC - PLASMA OUTPUT BOARD Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC G-3 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC G-4 ELECTRICAL DIAGRAMS G-4 SCHEMATIC-POWER PC BOARD NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
MAKE FROM S19399 (MAKES 24 BOARDS) NOTE: BLANK SHEARING TOLERANCE SEE P.C. BOARD ASSEMBLY REQ'D PART NO. 1 SEE BLANK 2 1 S19365-15 RIGHT ANGLE HEADER 3 3 oz E2861 SEALANT ITEM 1 Ch'ge. Sht. No. MANUFACTURED AS: LED7 Q4 LED3 L10721-1A0 R20 LED4 R18 R19 R17 R16 LED8 LED5 R15 LED6 R12 1.00 R4 DISPLAY 1.40 LED9 IDENTIFICATION CODE LED2 LED1 R8 R14 C5 DZ1 C4 ENCAPSULATE WITH E1844 R13 R9 C3 Q3 R10 R11 Q2 R5 C2 R6 R7 C1 R2 R1 R3 MAKE PER E1911 Q1 0 N.C.
Return to Master TOC ELECTRICAL DIAGRAMS G-6 SCHEMATIC - DISPLAY PC BOARD Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC G-6 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
Return to Master TOC ELECTRICAL DIAGRAMS G-7 SCHEMATIC - CONTROL PC BOARD Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC G-7 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
Return to Master TOC Return to Section TOC G-8 G-8 ELECTRICAL DIAGRAMS PC BOARD ASSEMBLY-CONTROL (G3328-1) ITEM REQ'D PART NO. C1 1 S13490-92 C2,C8,C10,C13,C14,C17,C20 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 1 S13490-121 C4,C18 2 S13490-63 .47/50 C5 1 S13490-71 100/50 C6 1 T11577-52 1000/35 .0047 or .005/1400 C7,C9 2 S13490-93 27/35 C15,C16,C32,C33,C42 5 S16668-11 .
Return to Master TOC ELECTRICAL DIAGRAMS G-9 PC BOARD ASSEMBLY-CONTROL (G3328-2) Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC G-9 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.
Return to Master TOC ELECTRICAL DIAGRAMS G-10 PC BOARD ASSEMBLY-OUTPUT (G3326-1) Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC G-10 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.
Return to Master TOC ELECTRICAL DIAGRAMS G-11 PC BOARD ASSEMBLY-OUTPUT (G3326-2) Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC G-11 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.
Return to Master TOC Return to Section TOC G-12 G-12 ELECTRICAL DIAGRAMS PC BOARD ASSEMBLY-POWER (G3172-1) D7 J10 C1,C5,C8,C11 4 S16668-6 4700pF/50 C2,C6,C9,C12 4 S20500-4 .0047/1000V C3,C4,C14 3 S16668-5 .022/50 C7 1 S13490-93 27/35 C10 1 S16668-9 150pF/100 C13 1 S13490-130 .
Return to Master TOC ELECTRICAL DIAGRAMS G-13 PC BOARD ASSEMBLY-POWER (G3172-2) Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC G-13 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.
We need to know if there are errors in our manuals. We also value any suggestions as to additional tests or procedures that would make this SVM a better tool for you. If you discover new or different “Problems or Symptoms” that are not covered in the three column troubleshooting chart, please share this information with us. Please include the machine’s code number and how the problem was resolved. Thank You, Technical Services Group Lincoln Electric Co. 22801 ST. Clair Ave.
