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Procut25 Service Manual - Red-D

1. TET WORK CLAMP 8 IRG4BC30W D10 Lout ES WRK gt b g C26 5 240uH 5 8 2 T swt BER RL AC AC E dE DS 5 A o S t p 52 300uH Ri Rust 5 PRI sec 12VDC TRANSFER B 10 10W 222 ter ot RUS ab 3 0112 m 5 T zz RL2 CP 2 15 E E AC AC ele a 4 d Tab RLI R24 vi RL A 3 Q2a b c Ti5VAG e 5 IRG4BC30W z HE u SHUNT EL 3 3 Svo c13 v m e 0 4 y _ 2 SH SH RL1 m 3 CN2 MEET 1 1 oe 5 2 E Li 4 4 2vDd 6 Main Inverter Board Solenoid 2 Input T Voltage Board 1516121814 1 114 197 19242123 8 1 1 2 3 4 Tal 7 1 lt m Br ke S bs M zi IS l fm IS 2 2 IP Ie ale lt 2130 lt 5 lt 21 o IS Go lo p 2 E 5 218 lo 5 SP m 2 2 15 15 A m le ko e 0 lt lt 20 2 mm 5 9 een 5 lt y y 8 6 179 3 1 21814 7 154 115 161012 13 23222 zt O o Jo L 1 12VDC H A Display LED s Ir Purge Solenoid Switch 1 Output Control Control Board PRO CUT 25 LINCOLN 5
2. SPECIFICHE DI COLLAUDO PC 006 KSA ITEM rev S sd ESEGUIRE LE PROCEDURE DI COLLAUDO PC 006 APPLICARE SILICONE RIF 1 INTORNO Al CONDENSATORI COME INDICATO PER UN ALTEZZA DI 1cm N C APPLICARE SILICONE RIF 1 SUI PIN DEL CONNETTORE J1 COPRENDOLI COMPLETAMENTE PART 1 N D APPLICARE SILICONE RIF 1 TRA LA SCHEDA PWM E I CONDENSATORI C7 E C13 COME INDICATO PER UN ALTEZZA DI 2cm N E APPLICARE SILICONE RIF 1 TRA LA SCHEDA PWM E LA SCHEDA INVERTER PER UN ALTEZZA DI 0 5 N F ISOLARE FASTON INDICATI EL WRK E NZL IL CONNETTORE J1 E LE 2 PIZZOLE DI TERRA CON NASTRO ADESIVO COME INDICATO NEI PART 1 2 3 N G VERNICIARE RIF 2 LA SCHEDA PER IMMERSIONE VEDERE PROCEDURA 008 PRESTANDO PARTICOLARE ATTENZIONE AFFINCHE IL LIVELLO DELLA VERNICE CORRISPONDA A QUANTO INDICATO IN PART 4 N H APPENDERE LA SCHEDA IN POSIZIONE VERTICALE VEDERE PART 5 FINO A QUANDO SMETTE DI GOCCIOLARE N APPENDERE LA SCHEDA IN POSIZIONE INCLINATA VEDERE PART 6 FINO A QUANDO RISUL
3. WORK CLAMP 3 GORE Lout CERE IRG4BC30W 010 AIL BS WRK D wa EUN 2 5 dl 240uH 7 5 swt AC 7 2 45 1 8 L1 A LS RL Jt ES pum 8 300uH MERE ot TE PRI SEC 12VDC TRANSFER RL2 CP mg as 10 10W Lie Tc ST D117 z o o S gt E 2 5 pru zl d AC eS D z Miss R24 vi RL2 3 Q22 b c 6 8k 5W 9 VENAS Ei IRG4BC30W ss E SHUNT EL 22 v2 Ti 2 C13 Y T sov J SH SH RLI a m CN2 CNA PT 1 1 gt Ryo 2 a m u 4 4 5 2VD 6 Main Inverter Board Solenoid 2 Input Voltage Board 1516121814 1 114 137 19242123 8 17 1 2 3 4 hol 5 E la e z lge P 8318 EL O fo SL ssp ns ieee ppm mm 5 5 gt 55 2 lo aag 7 y y 8 6179 3 1 2 18147 154 11 5 16101213 28222 lo E O JO j 12VDC 1 Ai Display LED s Ir Purge Solenoid Switch 1 Output Control Control Board CONTROL BOARD The control board receives status and analog feedback signals from the inverter board input board and various sensors The control circuitry interprets these signals makes decisions and changes the machines mode and output to satisfy the requirements as defined by th
4. J S CN CA OV 115V 230V 11 12 98 Y E LINCOLN ELECTRIC ITALIA gt o RO c6 RIS SPECIFICHE DI COLLAUDO 005 SCHEMA ELETTRICO 98056rev4 NON MONTARE SEGUENTI COMPONENTI R11 R12 IC3 C7 TOLLERANZE 0 2 SALVO DOVE ESPRESSAMENTE INDICATO VIETATA LA DIVULGAZIONE NON AUTORIZZATA DEL PRESENTE DOCUMENTO contains proprietary information owned by LINCOLN ELECTRIC ITALIA S R L and is not to be reproduced disclosed or used without the express permission of LINCOLN ELECTRIC ITALIA S R L LINCOLN ELECTRIC ITALIA s r l FAVORAZION CELLE LIGURE SV ITALIA SCHEDA 5 25 090699A SCALA DATA 02 12 98 NUMERO DI DISEGNO DATA DISEGN C D APPR 0 WO505600 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 Elec
5. la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place Mar 93 PRO CUT 25 LINCOLN 5 iv MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page A ms i iii Installation ede a s aes t e Pa A e ellos Section A Technical Specific ations e ette s te 2 Safety Precautions Iter uc Debate redeo ee ee rte oput dit A 3 Select Proper Location iusios re e DP Gba Perdido mer mate tant A 3 Seed EP A 3 E prts A Re me A ER ERR ERR E IE UT EE ERE A 3 High Frequency Interference Protection sn A 3 Input Electrical Gonfiectiors ce Dope aad sleek td eg i ERR ED E etn Rd A 3 Gas Inp t Connections c t le da code e A 4 Output Conhectioris ac eee beet ec BER eee e EOM D tege A 4 ERA 4 Operation ata Section B Safety Pr cautions ded a ted eee rn urn B 2 Description p e e B 2 Preheating Temperature sise B 2 User Responsibilities iia etm a b teet dei td ae tte tuens B 3 Operational Features and Controls eene B 3 Design Features and Advantages ii B 3 Cutting C apability ized tdem ree ene C ae ERE sra B
6. ottiene ai od ie A 4 Output Connections rire itte nt Dh irre een t eh Mie a beca A 4 TONG OSCE O 4 PRO CUT 25 LINCOLN 5 A 2 INSTALLATION ida TECHNICAL SPECIFICATIONS PRO CUT 25 K1756 1 INPUT SINGLE PHASE 60 HERTZ ONLY Standard Voltage 10 Input Current at Rated Output 115 230 1 50 60Hz 15A 20 26 7A 60 37 7A0 35 15 A 100 19 A O 60 RATED OUTPUT Duty Cycle 2096 on 115 V ECTS 6096 on 115 V 20A 10096 on 230 V 20A 3596 on 115 V 25A 6096 on 230 V 25 A OUTPUT Current Open Circuit Pilot Current Range Voltage 12 25 Amps 400 VDC 12 Amps REQUIRED GAS FLOW RATE REQUIRED GAS INLET PRESSURE 55 PSI 240 SCFH 65 to 150 PSI 3 8 Bar 6800 LHR 4 5 Bar TO 10 3 Bar RECOMMEND INPUT WIRE AND FUSE SIZES For all plasma cutting applications Based on U S National Electrical Code Ambient Temperature 30 C or Less Output AC Input Input Cord Fuse 75 Voltage Plug Super Lag Copper Wire in Conduit at Size Circuit Breaker AWG IEC Sizes 50 60 Delay Type Hertz 2 Input Supply Wires 1 Ground Wire 2301 10 6 20P or 6 30P or 6 50P 20 AMPS 14 2 5 mm 14 2 5 mm 115V 19 5 15P or 5 20P or 5 30P or 5 50P 15 AMPS 12 4 mm 12 4 mm 115V 19 5 20P or 5 30P or 5 50P 20 AMPS 12 4 mm 12 4 mm 115 10 5 30P or 5 50P 30 AMPS 12 4 mm 12 4 mm PHYSICAL DIMENSIONS Weight Including Torch Cable 35 Ibs 15 9 kg Included with machi
7. tor cT A 5 Len f 0114 T gt RL2 T CP 5 re L 2 7 AC RS Tab RL1 R24 vil A 3 Q2a b c 6 8k 5W m 115VAC 2 IRG4BC30W z Hs u SHUNT EL 3 3 Sve Ti 2 C13 v ENS 2 SH SH RL1 a E CN2 CN3 PT 115V 1 oo 3 L1 4 2VD Hain Main Inverter Board Solenoid 2 npu Voltage Board 15 16 12 18 14 1 114 137 19242123 8 17 1 2 3 4 OE lt zr 21 2 ME E lt Z lo SIP jele E Is ole 55 4 Im ome m 8 2 e oom Prey y i rr 6179 3 1 2 1814 7 15 4 11 5 16101213 23222 LJ 12VDC 1 LU A Display LED s Ir Purge Solenoid Switch 1 Control Board Output Control PRECHARGE AND PROTECTION The input voltage is rectified by the input rectifier on the inverter board The resultant DC voltage is applied to the filter capacitors through the automatic reconnect of the input board The input board also contains precharging circuitry for the safe charging of the input filter capacitors Once the capacitors are precharged the input board activates the RL3 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 IGBTs supply the main trans former primary winding with DC current flow The inverter board also monitors the filt
8. vided 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 LIN LN 3 ine LINCOLN 9 man PRO CUT 25 ELECTRICAL DIAGRAMS G7 PC BOARD ASSEMBLY INPUT BOARD Iz Codice Descrizione Rif topografico 1020056 5 5 6 0 25W 5 R9 1020150 RES 15 OHM 0 25W 5 R7 1021470 RES 470 OHM 0 25W 5 R5 R6 R8 1024470 5 470K OHM 0 25W 5 R4 1124330 RES 330K OHM 0 5W 5 R2 R3 221470 RES 47 OHM 1W 5 R13 1521180 5 180 OHM SW 5 R10 701040 5 10 OHM 10W 10 R1 W3042470 COND CER 4700pF 100V X7R 10 C4 W3043105 CER 0 1uF 50V 5 08 10 C5 W3083470 470nF 630V 10 C3 W3410220 COND EL RAD 220uF 100V 20 C6 D D L LATO COMPONENTI W3416472 COND EL RAD 220uF 25V 20 C2 W3435150 COND EL RAD 1500uF 35V 20 1 W4004148 01000 1 4148 04 05 W411000E PONTE 1 100 1 5 1KV 01 02 03 W4207907 01000 ZENER 5 1V 1W 0 1 W4300184 TRANS NPN_TO 92 BC 184 Q2 04 W4304408 TRANSISTOR_NPN_D44H8 01 03 W450062A OPTOISOLATORE 17 3 2 W4607805 INTEGRATO 7805 1A 5V W05338A1 SCHEDA CSI 20U logica W5998057 TRASFORMATORE AUSILIARIO W6000009 FASTON MASCHIO PER
9. CAPACITOR TERMINALS RIGHT SIDE OF MACHINE INSULATED PLIERS INSULATED GLOVES POWER RESISTOR PRO CUT 25 LINCOLN 5 TROUBLESHOOTING amp REPAIR MAIN INVERTER BOARD RESISTANCE TEST Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION This test will determine if the main inverter board has any shorted or leaky power diodes or Insulated Gate Bipolar Transistors IGBT s Also it will indicate if P1 is shorted or open MATERIALS NEEDED Analog Volt Ohmmeter Wiring Diagram 7mm Nut Driver 4mm Allen Wrench Crescent Wrench This procedure takes approximately 25 minutes to perform PRO CUT 25 LINCOLN 5 dia TROUBLESHOOTING amp REPAIR Pid MAIN INVERTER BOARD RESISTANCE TEST continued FIGURE F 2 LEAD 2 NZL WRK LEAD 3 EL gt Plug J1 Harness Plug RIGHT SIDE OF MACHINE TEST PROCEDURE 1 Remove ma
10. ELECTRIC SHOCK KILL Turn off machine at the disconnect Switch on the front of the machine before tightening cleaning or replac ing consumables gt Change consumables as required THERMAL PROTECTION Thermal Detection Devices protect the machine from excessive operating temperatures Excessive temper atures may be caused by a lack of cooling air or oper ating the machine beyond the duty cycle and output rating If excessive operating temperatures should occur the yellow thermal LED will light and the Detection Devices will prevent output voltage or cur rent These Detection Devices 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 peri od 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 correct ed A protection circuit is included to monitor the voltage across filter capacitors In the event that the capacitor voltage is too high the protection circuit will prevent output REPLACEMENT OF INTERNAL FUSE The PRO CUT 25 has additional protection provided to some circuits through an internal fuse For replace ment of this fuse proceed as follows 1 Turn off the power to the unit and remove the input plug 2 Allow
11. manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION This procedure will help the technician determine if the solenoid is functioning properly MATERIALS NEEDED 4mm Allen Wrench 7mm Nut Driver 12 VDC 3 Amp Power Supply Volt Ohmmeter Crescent Wrench This procedure takes approximately 20 minutes to perform PRO CUT 25 LINCOLN F 28 TROUBLESHOOTING amp REPAIR AIR GAS SOLENOID TEST continued FIGURE F 12 AIR SOLENOID Air Solenoid HO LEFT SIDE OF MACHINE TEST PROCEDURE 1 5 Remove input power to the PRO CUT 25 machine Remove carrying handle using a 4mm allen wrench Using a crescent wrench carefully remove the plastic nut from around the pressure regulator located on the top of the machine Using a 7mm nut driver remove the case wraparound Perform the Input Capacitor Discharge Procedure detailed earlier in this section Locate the air solenoid and leads Carefully remove the two leads from the Solenoid See Figure F 12 e 00000000 10000000 Check the coil resistance of the solenoid at the two terminals Normal resistance is approximately 13 ohms If the resistance is abnormal the Solenoid may be def
12. 1 Maximum output requires a 30 amp input circuit and breaker Refer to the Technical Specifications for proper input circuit guidelines 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 65 PSI for 15 or 25 torches Release the Purge button The gas will immediately turn off The pressure gage 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 Exceptions the first time that the trigger is pulled after the machine is turned on or after a thermal tripout will be ignored This is a safety feature to prevent the pilot arc from firing unexpectedly or if the torch button is pressed because it is laying up against something The other exception is if 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 0 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 When the arc is brought within 1 8 1 4 from the work piece
13. 12 Check for the presence of approximately 15VAC at pins 1 and 2 of plug CN1 See Figure F 7 Figure F 7 Input Board Test Points Fan Leads 12345678 lt PLUG PRO CUT 25 LINCOLN 5 F 20 N OTE S F 20 PRO CUT 25 LINCOLN 5 F 21 F 21 TROUBLESHOOTING amp REPAIR MAIN INVERTER BOARD VOLTAGE TEST Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION This test will help determine if the main inverter board is receiving the correct input voltages and if the correct regulated voltages are being processed and maintained by the main inverter board MATERIALS NEEDED Volt Ohmmeter 7mm Nut Driver 4mm Allen Wrench Crescent Wrench This procedure takes approximately 30 minutes to perform PRO CUT 25 LINCOLN 5 F 22 TROUBLESHOOTING amp REPAIR pos MAIN INVERTER BOARD VOLTAGE TEST CONTINUED TEST PROCEDURE 1 R
14. 24 A Output Control Control Board 111 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine PRO CUT 25 G 3 ELECTRICAL DIAGRAMS SCHEMATIC CONTROL PRINTED CIRCUIT BOARD SHEET 1 LINCOLN B 5 4 3 e 1 Hybrid 2 12V_IN 8V Hykrid 1 N LM7808 11115 5 14 27 45 1 B 2 R10 BD438 R32 10k 14 48V 680 A RIS R17 R1 R3 R4 R6 713 gt 16k 470k 8 2k 10k 22k 220k D R2 12V_IN 12V_IN 15i THERMAL LED Rit lu LOW ERROR gt 500 25 E R13 R5 ZX R8 10k 2 2k zi 1k 5 2138 4 5 12V_IN 34 y PIP DETECT A 2 OUVLDAD SAFETY CHK o LM3580 LOW ERROR 25 74 H LM358D LOW ERROR gt _ a2 TEN END 26 iok 5 m R9 R33 R16 Za imd lt 470 E 10k CF40 10k Ci 1 cre C4 cs Q4 100u LM336D 47u 1004 1004 gt vss 58 125 50 12550 LOW VOLTAGE DETECT
15. 4 Consumable Life 2 cab cete ede n ae ER Dee Pee B 4 LIMITATIONS ec A AAA a B 5 Controls and Settings vicio tcs B 5 Pilot Are DISCUSSION uere e bereiten eor e ese t e B 6 Procedure Recommendations sise B 7 CC 7 Suggestions For Extra Utility From The Pro Cut System B 7 Accessories iio eaten aia ds Section C Maintenance rep aa leds eee eei d a adve ba ng ex td Section D Theory of Operation tad RR LM doi te Hh e Ml Section E Troubleshooting and Repair Section F How to Use Troubleshooting Guide F 2 Troubleshooting Guide ete etd etd ae teda I a E RR R c F 4 Test Procedures iios eee epe or ret perd niter pile F 9 Replacement Procedure S onns tata bbb esta F 29 Electrical Diagrams creen De e bee AREE Section G Parts Manual ool eie a ica P 357 Series PRO CUT 25 LINCOLN 5 iv NOTES PRO CUT 25 LINCOLN 5 Section A 1 TABLE OF CONTE NTS Section A 1 INSTALLATION SECTION Installation Technical Specifications en A 2 Safety Preca tiohs drei A ih A 3 Select Proper Location issue A 3 sere A 3 nenn terre reer rete 3 High Frequency Interference Protection A 3 Input Electrical Connections uses 3 Gas Input Connections
16. C S V2 AC AC CP W6110108 MODU2 8X1 1 MAINS 115 230Vac FISSARE L ISOLANTE ALLA SCHEDA CON SILICONE Sola xi x anQ e ojaiaisers r2 N N CA FUSE 1A 000 1959 gt N N T C W7005600 STAMP SIPC25 REV 02 W7130220 RELE 2 SCAMBI 2A 6Vdc F P N Y N W7162430 LE 3 SCAMBI 16A 110 W7165610 30A 12Vdc x C S W7301000 FUSIBILE RITARDATO 1A W7900630 ZA PER FUSIBILE W8093008 VITE ACCIAIO ZINC M3x8 W8100003 RONDELLA ACCIAIO W8110003 RONDELLA DENTATA INT M3 W8110004 RONDELLA DENTATA INT M4 W8111004 RONDELLA M4 OTTONE W8200003 DADO ACCIAIO ZINCATO M3 W8210004 DADO OTTONE M4 W84A4355 ISOLANTE ISOLCART W86A4406 TORRETTA M4x8 M M W9108165 DISSIPATORE TRANS 10220 W1020100 RESISTENZA 10 OHM 0 25W 5 23 LATO 7 Ss 4 pos I 2 20 20 o U 9DAOCZ NVA 2 SIPC25 W7005600 REV 2 CA
17. Carefully test for 12VDC at test points 12 Carefully check for the presence of C7 See Figure F 9 See the Wiring 8VDC at C19 test points If not correct Diagram This is the rectified and the control board or associated wiring regulated supply for the pulse width may be faulty See Figure F 9 modulation circuit See the Wiring Diagram 11 Carefully test for 12 at C18 test points If it is not correct the control board or associated wiring may be faulty See the Wiring Diagram See Figure F 9 Figure F 9 Test Points P2 C17 L O LEAD 2 NZL WRK gt LEAD 3 EL gt Plug J1 gt A Harness Plug RIGHT SIDE OF MACHINE PRO CUT 25 LINCOLN 5 iic TROUBLESHOOTING amp REPAIR 55 TORCH CONTINUITY AND SOLENOID TEST Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION This procedure will help the technician determine if the torch cabl
18. detailed in the beginning of this manual PROBLEMS SYMPTOMS Major physical or electrical dam age is evident when the sheet metal cover s are removed POSSIBLE AREAS OF MISADJ USTMENT S OUTPUT PROBLEMS 1 Contact your local authorized Lincoln Electric Field Service Facility for technical assistance F 4 TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION 1 Contact the Lincoln Electric Service Department 1 800 833 9353 WELD Machine is dead no output no fan no status indicator lights Make sure that the input power switch is in the ON position Check the input voltage at the machine Input voltage must match the rating plate Check for blown or missing fuses in the input lines and the 1A slow blow fuse on the input board Check the input power switch for proper operation Check the leads associated with the power switch for loose or faulty connections See the Wiring Diagram Check all connectors and wires for loose or faulty connections 4 Perform the Input Voltage Board Test Machine is malfunctioning no output no status indicator lights fans run Check the input voltage at the machine Input voltage must match the rating plate Check all connectors and wires for loose or faulty connections See Wiring Diagram 2 Perform the Input Voltage Board Test 3 The control board may be faulty Replace CAUTION If for a
19. remove Pliers may be necessary CAUTION 10 Using a 7mm nut driver remove the two leads from terminals A and B on the Be sure to follow the recommended static free input board NOTE The lead posts on methods for the Input Board are labeled with an A Failure to do so can result in permanent damage to and a B so label the lead wires the equipment accordingly upon removal Be careful not to misplace washers when bolts are removed PRO CUT 25 LINCOLN 5 F 35 11 12 13 14 TROUBLESHOOTING amp REPAIR F 35 INPUT BOARD REMOVAL amp REPLACEMENT continued FIGURE F 17 INPUT BOARD REMOVAL Mounting Screws Switch Leads gt 4 AC isl 1 AC ES T iit Fan AE Leads 7 DM 4 Multi colored Plug Mounting Screws Using a 7mm Nut driver remove the 15 Reconnect the harness plug four mounting nuts from the corners of the Input Board Be careful not to lose 16 Reconnect the fan leads to the Input the washer behind each nut Input Board Be sure that leads are Board can be removed after these four connected to their original positions nuts are removed 17 Replace the case wraparound After replacement of the Input Board replace the four nuts and 18 Replace the plastic nut from around the washers previously removed pressure regulator Do Not Over from the corners of the board tight
20. the machine to stand for 5 minutes to let the input capacitors discharge or perform the Capacitor Discharge Procedure after removing the case wraparound cover 3 Remove the machine cover 4 Replace the blown fuse with a new 1 0A 500V slowblow fuse NOTE If the fuse blows again after power is restored the cause could be an internal breakdown in the power unit In this case perform the trouble shooting procedures to determine the problem PRO CUT 25 LINCOLN ND Central Metal Wall Main Board Input Board Control Board Fan Case Wraparound Torch MAINTENANCE FIGURE D 2 MAJOR COMPONENT LOCATIONS PRO CUT 25 LINCOLN 5 Section E 1 Section E 1 TABLE OF CONTENTS THEORY OF OPERATION SECTION Theory of Operation iicet dd e e tos Section E General Description b eatin de quede dere e E 2 Input Line Voltage and Auxiliary Transformer E 2 Precharge and Protections nde ede Re et e ERE Dd eee REM d e ine Ege E 3 Main Transformer A e us Ede RU RE E 4 Output Secton and Torch e nbl E 5 Control Board nn EE E 6 Protection CiU ha duet i aer tt e Hebe E 7 Overload Protector recoil bed titia E 7 Thermal Protec iio Aoi E 7 Accidental Operation Protection sens E 7 Safety Parts In Place Protection ss E 7 Insulated Gate Bipolar Transistor IGBT Operation mmm E 8 FIGURE E 1 PRO CUT 25 BLOCK LOGIC DIAGRAM
21. warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION This test will help determine if the correct input voltage is being applied to the input board and will also determine if the correct voltages are being processed and regulated on the input board MATERIALS NEEDED Volt Ohmmeter 7mm Nut Driver 4mm Allen Wrench Crescent Wrench This procedure takes approximately 20 minutes to perform PRO CUT 25 LINCOLN 5 1 TROUBLESHOOTING amp REPAIR INPUT BOARD VOLTAGE TEST CONTINUED TEST PROCEDURE Remove input power to the PRO CUT 25 machine Remove carrying handle using a 4mm allen wrench Using a crescent wrench carefully remove the plastic nut from around the pressure regulator located on the top of the machine Using a 7mm nut driver remove the case wraparound Perform the Capacitor Discharge Procedure detailed earlier in this section Visually check for burned or damaged components on the input board If any components are physically damaged or determined to be faulty except the fuse the input board should be replaced Check fuse F1 1 amp Replace if defectiv
22. 1 30 C17 LOW RESTRIKE gt R35 lu 10k R37 R29 R30 R31 10k rt PREFLOW 24 20 R38 SAFETY LO TE 47k 270k 10k Luv LM324D 10k lt LOW ERROR D5044 85 RESTRIKE TS TRIG o 4 39 9 see LM324D CHIGH RESTRIKE TS D5014 D501B D tecT LM324D 10k R87 10k PIP DISABLE SAFETY LOCKOUT u ARC RESTRIKE RESTRIKE TS 8V A R97 R99 ev R69 R71 lt gt 47k B 10k 100k AM cal R96 10u R73 PREFLOW o i OGAS ENABLE ay 5 nd ny CHIGH ENABLE gt EIN US 8 R70 z 4 8 1 12 18 a TRIG TEE E PURGE MS R79 D36 eN USA R74 9 150 x gt 1 3 44 32 48 05 10k 3 7 CF4 1 1 LM324D 470 L cre SAFETY LO 07 R67 lt 7 23 A RESTRIKE TS PRERLON 7 9 136 OPRESSURE SW 29 MS DRIVER R82 R84 SAFETY LO 8V Des lt RI03 4 R100 21 30 R68 05 R77 R78 16k 100k 22 49 470 470 40 PIP BETECT 5 gt R72 1k 1k OTS DRIVER 10k E cp i 0510 R102 3 44 GAS ENABLE N As a 4 K 52 TRIG 4 4 US R101 5 125 50 D5108 7 p o8 47 PURGE TS 4 hy GAS ENABLE amp POSTFLOW TIMER LM358D 47k R81 R104 Lincoln Electric Italia s r l 390k 220 Celle Ligure SV Italia cee 10u Pro Cut 25 Control Boord 4 4 NV 1 25 50 Hybrid 1 126 Document Number ev TS ENABLE amp TURN OFF DELAY 92099 0 lo ter Tuesday April 13 1999 heet 2 OF 3 5 4 3 2 1 NOTE This diagram is for reference only It may not be accurate for al
23. COLN Section F 1 2 TROUBLESHOOTING amp REPAIR HOW TO USE TROUBLESHOOTING GUIDE 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 three main categories Output Problems Function Problems and LED Function Problems Step 2 PERFORM EXTERNAL TESTS The second column labeled POSSIBLE AREAS OF MISADJ USTMENT 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 sp
24. 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 When the pilot arc is started a slight impulse will be felt in the torch handle This occurrence is normal and is the mechanism which starts the plasma arc This impulse can also be used to help troubleshoot a no start condition PRO CUT 25 LINCOLN 5 ud OPERATION i PROCEDURE RECOMMENDATIONS When properly used plasma arc cutting is a very eco nomical process Improper use will result in a very high operating cost 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 General In All Cases the inside bottom surface of the nozzle This will Follow safety precautions as printed throughout this operating manual and on the machine f piercing is required s
25. E 2 THEORY OF OPERATION E 2 FIGURE E 2 INPUT LINE VOLTAGE AC WORK CLAMP Q1a b c zx IRG4BC30W Lout ES A S WRK 240uH y ll 4 300uH INPUT 12VDC TRANSFER CP CP D15 RL1 115 230 1 50 60 VAC FN1 Input Voltage Board ot 1500 uF 250V gt E v 15K 3W 15K 3W Q2a b c IRG4BC30W SHUNT 1500uF 250V cra SH SH 2VD Main Inverter Board Solenoid 2 gt S ES 21 gt El T co 14 MENE 4 SUASIT A MS 13395 MS A8 0 9 235 E dVOTAO 3 MSH3JSNVHI 145 1 y3Alya 105 1 2 105 9959181 indino 110 U3dIM 104 104 104 le fe ONT eil al e ES 12VDC j a Display LED s Purge Solenoid Switch 1 Control Board Output Control GENERAL DESCRIPTION The PRO CUT 25 is an inverter based constant current continuous control plasma cutting power source The control system has a safety mechanism to insure that the nozzle and electro
26. L BOARD REMOVAL AND REPLACEMENT continued FIGURE F 13 CONTROL BOARD LOCATION Control Board PROCEDURE 1 Remove input power to the PRO CUT 25 machine 5 Perform Capacitor Discharge Procedure 2 Remove carrying handle using a 4mm allen 6 Using a very small flathead screwdriver a thin wrench knife blade carefully remove the red plastic cap from the front of the plastic OUTPUT knob located 3 Using a crescent wrench carefully remove the on the front of the machine See Figure F14 plastic nut from around the pressure regulator located on the top of the machine 4 Using a 7mm nut driver remove the case wrap around FIGURE F 14 SMALL RED CAP REMOVAL Small Red Cap PRO CUT 25 LINCOLN 5 dn TROUBLESHOOTING amp REPAIR F31 CONTROL BOARD REMOVAL AND REPLACEMENT continued 7 A nutis located under the red plastic piece thatyou 8 Next to the knob is a Red button that reads previously removed Loosen this nut with a 6mm PURGE Remove it by gently pulling nut driver and remove Plastic alignment spacer may come off with knob FIGURE F 15 CASE FRONT SCREW REMOVAL 3 Screws CAUTION Be sure to follow the recommended static 11 Carefully remove the plug and lead assembly from free methods for handling printed circuit the control board boards Failure to do so can result in per 12 At this point the control board is ready fo
27. LMP 2855 HLMP 2450 HLMP 2450 HLMP 2755 HLMP 2755 HLMP 2450 HLMP 2450 HLMP 2755 HLMP 2755 HLMP 2350 HLMP 2350 HLMP 2655 HLMP 2655 MI y y y Y Y y y Y y Y 5 o n o 0 o o M LDIA LDIC Loa LDeB al LD3A w LD3C LD4B LDSA LDSC LD6A 1168 LDA v LD7C LD8A LD8B HLMP 2550 HLMP 2550 HLMP 2855 HLMP 2855 HLMP 2450 HLMP 2450 HLMP 2755 HLMP 2755 HLMP 2450 HLMP 2450 HLMP 2755 HLMP 2755 HLMP 2350 HLMP 2350 HLMP 2655 HLMP 2655 Y Y Y y y Y Y Y Y y Y Y Y N N N N LED3 OLED4 Lincoln Electric Italia s r l Celle Ligure SV Italia Pro Cut 25 Control Board ize Document Number 99039 later Tuesday April 13 1999 heet 3 3 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual PRO CUT 25 2 ELECTRICAL DIAGRAMS d PC BOARD ASSEMBLY MAIN INVERTER BOARD Codice Descrizione W7900006 SIGILLANTE SILICONICO W7900010 VERNICE ISOLANTE 220 WO799084 ADESIVO PER INVERTER N A N G N J 77 u S ime W ur A
28. O CUT 25 machine 2 Remove carrying handle using a 4mm allen wrench 3 Using a crescent wrench carefully remove the plastic nut from around the pressure regulator located on the top of the machine 4 Using a 7mm nut driver remove the case wraparound 5 Be careful not to make contact with the capacitor terminals located at the top of the main inverter Board 6 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 7 Locate the eight capacitor terminals located at the top rear of the main inverter board See Figure D 1 8 Use electrically insulated gloves and insulated pliers Hold the body of the resistor and connect the resistor leads across the two capacitor termi nals Hold the resistor in place for 10 seconds DO NOT TOUCH CAPACITOR TERMINALS WITH YOUR BARE HANDS 9 Repeat the discharge procedure for the other capacitors 10 Check the voltage across the terminals of all capacitors with a DC voltmeter Voltage should be zero If any voltage remains repeat this capacitor discharge procedure FIGURE D 1 LOCATION OF INPUT FILTER CAPACITOR TERMINALS CAPACITOR TERMINALS RIGHT SIDE OF MACHINE INSULATED PLIERS INSULATED GLOVES POWER RESISTOR PRO CUT 25 LINCOLN 5 ex MAINTENANCE pud 44 WARNING ELECTRIC SHOCK can kill Have an electrician instal
29. OR DISCHARGE PROCEDURE Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION This procedure will drain off any charge stored in the four capacitors that are part of the Inverter 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 4mm Allen Wrench Volt Ohmmeter 7mm Nut Driver Crescent Wrench Insulated Gloves Insulated Pliers High Wattage Resistor 25 to 1000 ohms 25 watts minimum This procedure takes approximately 15 minutes to perform PRO CUT 25 LINCOLN 5 F 9 TROUBLESHOOTING amp REPAIR F 10 INPUT FILTER CAPACITOR DISCHARGE PROCEDURE continued ELECTRIC SHOCK can kill Have an electrician install and service this equipment Turn the input power off at the fuse box before work
30. PROTECTION The PRO CUT 25 has protection circuits to detect the proper connection of the torch and the proper installation of the consumables If an error is detected with either of these two items the Safety status LED will be turned on and the output of the machine will be disabled The PRO CUT 25 must be turned off and the problem must be corrected before normal operation can occur PRO CUT 25 LINCOLN 5 E 8 INSULATED GATE BIPOLAR TRANSISTOR IGBT OPERATION An IGBT is a type of transistor IGBTs are semicon ductors well suited for high frequency switching and high current applications Drawing A shows an IGBT in a passive mode There is no gate signal zero volts 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 THEORY OF OPERATION 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 pre
31. Purge momentary push button Air regulator and pressure gage included Parts in Place mechanism to detect proper installa tion of consumables and torch Latching Parts in Place mechanism Requires the operator to turn the machine off and then on to reset Preflow Postflow timing Preflow is eliminated if arc is re initiated in Postflow Thermostatic Protection Solid state over current protection Automatic reconnect for 115 VAC or 230 VAC inputs Dead front display for machine status Unique electrode and Vortech nozzle design for optimum cooling and long life Swirl texture inside Vortech nozzle for better start ing reliability and higher quality cuts PRO CUT 25 LINCOLN 5 2 OPERATION gi CUTTING CAPABILITY The PRO CUT 25 is rated at 25 amps at 35 duty cycle on a 10 minute basis If the duty cycle is exceeded a thermal protector 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 25 when cutting mild steel The graph plots cut thickness vs torch travel speed with a torch standoff of 0 15 Lincoln s PRO CUT 25 Cut Capacity Chart Recommended Torch Travel Speed IPM 80 of Maximum Speed 0 125 0 250 0 375 Metal Thickness Inches Figure B 1 CONSUMABLE LIFE The expected life for the PRO CUT 25 s electrode under normal operating conditions is approximately 1000 starts cuts An erosion of 060 is typical f
32. RO CUT 25 LINCOLN 5 7 Observe Safety Guidelines TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE detailed in the beginning of this manual PROBLEMS SYMPTOMS The gas pressure LED is lit POSSIBLE AREAS OF MISADJ USTMENT S LED FUNCTION PROBLEMS 1 Make sure there is at least 70 psi of air pressure connected to the gas connection at the back of the PRO CUT 25 Press the purge button and set the regulator to 65 psi Do not reset the air pressure while the air is off not flowing F 7 RECOMMENDED COURSE OF ACTION The pressure switch or associ ated wiring may be faulty See the Wiring Diagram The control board may be faulty Replace The Safety LED is lit Make sure the torch consum able parts are in place and in good condition Replace if nec essary Turn the machine off and then back on If the consumables are properly installed the safety LED will be off Check all connectors and wires for loose or faulty con nections See Wiring Diagram Torch Continuity and Solenoid Test Perform the Input Voltage Board Test The control board may be faulty Replace The thermal LED remains lit when the machine is turned on Check the input voltage at the machine Input voltage must match the rating plate Check all connectors and wires for loose or faulty con nections See Wiring Diagram A thermostat may be faulty Check or Replace See Wiri
33. RO CUT 25 LINCOLN 5 G 1 G 1 ELECTRICAL DIAGRAMS TABLE OF CONTENTS ELECTRICAL DIAGRAMS SECTION EME CT RICA DIAGRAMS O alan ri iia SECTION G WIRING DIAGRAM PROCUT 25 G 2 SCHEMATIC CONTROL PRINTED CIRCUIT BOARD SHEET 1 G 3 SCHEMATIC CONTROL PRINTED CIRCUIT BOARD SHEET 2 G 4 SCHEMATIC CONTROL PRINTED CIRCUIT BOARD SHEET G 5 PC BOARD ASSEMBLY MAIN INVERTER BOARD G 6 PC BOARD ASSEMBLY INPUT BOARD PRO CUT 25 LINCOLN 2 G 2 WIRING DIAGRAM PRO CUT 25 LINCOLN B INPUT 115 230 1 50 60 VAC Purge Switch ELECTRICAL DIAGRAMS WIRING DIAGRAM 26 E Pa ee dd A B Input Voltage Board Solenoid 1 15VAC 2 LISVAC 3 4 28VDC 8 1500uF 250V G 2 em IRG4BC30W 4 LES WRK 240uH 8 T2 SEE 412VDC TRANSFER D11 RL NZL 2 o C14 Q2a b c 6 8k 5W IRG4BC30W SHUNT EL 3 z a D C13 SH SH 4 CN3 1 gl ahoo o 2109 Main Inverter Board Solenoid 2 Display LED s ME 5 Im 9 2 2 e Ir Ie lt 316 O 1S 0 2 2 Im a Io lo 2 lo 8 Ojo 5 2 2a Ja 7 2 z mm P 20 m 1 2 1814 7 15 4 11 5 1610 12 13 23 22
34. SAFETY DETECT Hybrid 2 8V Hybrid 1 8V 8V 8V TRANSFER DUTPUT TRANSFER SW R59 10 33 37 R64 R42 R45 R47 Ej 10k 10k 470k 10k c 8 R62 R63 Ree R44 D5048 UAE R49 XZ 25144 390k 1k u 0 34 19 K 1 0106 100k D5148 R58 R46 1 a 220k s Q4 D509A R57 LM358D DGSE ZSne 12 MAX PILOT TIME DCV DETECT m MAX OCV TIME Vout 300k t LM358D LOW ERROR gt ica t LM324D lt LOW OCV T LM324D LOW ERROR gt R56 RES R41 R43 R48 18k LM 10k Ik 10k ARE 10k cis 19 L c15 c16 lu 10u CFS 2 2n 10u 5 9 125 50 Y 12550 PILOT ARC TRANSFER PILOT ARC TIME LIMIT OCV DETECT OCV TIME LIMIT B Hybrid 1 RTI D508A de Ye PREFLOW tw 20 2 GTI D4 tev RESTRIKE A 35 E D508B TRIG HIRO R53 R54 __ m dole PURGE TS ev 33 Dei U4B Dee RSS 3 A Di Sag 0 URGE MS MS MAIN SOLENDID ve 470 TS TORCH SOLENOID SAFETY CHK O TRANSFER SW ASS t OFURGE DEFAULT CAPACITOR 100n 25V PURGE lt LOW PURGE gt DEFAULT CAPACITOR VOLTAGE 16V TRANSFER SEEN i DEFAULT DIDDE BAS32L Vouto qur 9 RIS DEFAULT ZENER DIDDE TZMC2V4 TS DRIVER 47 47 DEFAULT RESISTDR 1 8W 1X OVLOAD gt 1 DEFAULT TRANSISTOR BC817 25 TPI QO L o TP8 DEFAULT SCR MCRO8BT1 TP3 RTICW 7 31 1 9 HRTICCW V do PRESSURE SW dr V6110193 5142745 LOW ERROR PBND Lincoln Electric Italia s n 14 27 Celle Ligure SV Italia 2 ces a Pro Cut 25 Co
35. SVM149 A April 2000 PRO CUT 25 For use with machine code numbers 10661 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind However your overall safety can be increased by proper installation and thoughtful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READ ING THIS MANUAL AND THE SAFETY PRECAUTIONS CON TAINED THROUGHOUT And most importantly think before you act and be careful SERVICE MANUAL LINCOLN World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com 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 pur chase a copy of Safety in Welding amp Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PER FORMED ONLY BY QUALIFIED INDIVIDUALS ELECTRIC SHOCK can kill 1 a The electrode and work or ground
36. TA ASCIUTTA AL TATTO N J LASCIARE ASCIUGARE LA SCHEDA PER 24 ORE DALLA VERNICIATURA DOPODICHE FARE IL TEST DIELETTRICO APPLICARE L ADESIVO RIF 3 SUL LATO SALDATURE COME INDICATO IN 7 PART 4 IL LIVELLO FASE 2 PAG 2 2 TT Ue LATO COMPONENTI TOLLERANZE 0 2 SALVO GI DOVE ESPRESSAMENTE INDICATO VIETATA LA DIVULGAZIONE NON AUTORIZZATA DEL PRESENTE DOCUMENTO ARRIVARE A This sheet contains proprietary information owned by LINCOLN ELECTRIC ITALIA S R L and is not to be reproduced disclosed or used without the express permission of LINCOLN ELECTRIC ITALIA S R L TOCCARE PIN DEL LINCOLN ELECTRIC ITALIA 1 ASSEMBLAGGIO COMPONENTI CONNETTORE 57 20020000 CELLE LIGURE SV ITALIA INVERTER 25 1006980 FDM SCALA DATA 17 02 1999 ego DATA VISTO DISEGN FDM CD APPR gt WO504400 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 pro
37. TER BOARD RESISTANCE TEST continued 9 Check Diodes 01 D2 amp D3 for shorts opens Keep in mind that unless these devices are electrically isolated from the circuit some resistance will be read in both polarities See the Wiring Diagram Figure F 4 LEAD 2 NZL WRK LEAD 3 EL Plug J1 Harness Plug RIGHT SIDE OF MACHINE D1 D2 amp D3 PRO CUT 25 LINCOLN 5 icd TROUBLESHOOTING amp REPAIR an MAIN INVERTER BOARD RESISTANCE TEST continued 10 Remove the torch consumables Shield 12 With the Torch Consumables removed test cup Nozzle and Electrode the snubber diodes D8 and D9 See the Wiring Diagram See Figure F 5 11 With the Torch Consumables removed test the output diodes 010 and D11 Seethe 13 Replace the torch consumables Wiring Diagram previously removed Check the resistance across output diode D11 The resistance should be very low near or at zero ohms This verifies that the pilot arc circuit is complete See the Wiring Diagram Figure F 5 LEAD 2 NZL WRK LEAD 3 EL Plug J1 RIGHT SIDE OF MACHINE PRO CUT 25 LINCOLN 5 F 16 NOTES PRO CUT 25 LINCOLN 5 F 16 TM TROUBLESHOOTING amp REPAIR INPUT BOARD VOLTAGE TEST 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
38. Test Perform the Main Inverter Board Voltage Resistance Tests The control board may be faulty Replace 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 repeat ed with subsequent trigger pulls Check the input voltage at the machine Input voltage must match the rating plate Make sure the torch consumable parts are in place and in good condition Replace if necessary Make sure there are no kinks or restrictions for air flow in the torch cable Make sure the air pressure is set at 65psi Check all connectors and wires for loose or faulty connections See Wiring Diagram 2 Perform the Main Inverter Board Voltage and Resistance Tests 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 con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD PRO CUT 25 LINCOLN 5 F 6 Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS The cutting arc starts but sputters badly POSSIBLE AREAS OF MISADJ USTMENT S FUNCTION PROBLEMS Make sure the operating proce dure is correct for the process See the of the manual Make sure the work clamp is connected tigh
39. ad 3 to Torch Pilot arc lead to 1 0 ohm maximum Torch consumables Nozzle nozzle in place Pin 1 to Pin 2 Torch trigger circuit 100K ohms minimum Torch trigger NOT Plug J 1 Red Leads pulled not activated Pin 1 to Pin 2 Torch trigger circuit 1 0 ohm maximum Torch trigger pulled Plug J 1 Red Leads activated Pin 3 to Pin 4 Electrode Solenoid 45 to 55 ohms None Plug J 1 Gray Leads Figure F 11 LEAD 2 NZL gt c WRK gt oU LEAD 3 EL gt Be 4 3 2 1 Harness Plug J1 Q 8 If any ofthe resistance checks are not correct the torch assembly may be faulty Repair or replace 9 With connector 1 disconnected from the P C Board carefully apply the 12 VDC supply to the electrode solenoid positive to Plug J 1 Pin 4 and Negative to Pin 3 The electrode solenoid should activate solenoid action in the torch handle Listen for the If the solenoid does not activate it may be faulty Replace See Figure F 11 10 Replace leads and plugs previously removed PRO CUT 25 LINCOLN 5 Tf TROUBLESHOOTING amp REPAIR on AIR GAS SOLENOID TEST 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
40. aker may blow in roughly 30 seconds or less depending on fuse or circuit breaker type To achieve 20 amp output with 115VAC input replace the 15 amp plug on the input cord with the supplied 20 amp plug and connect the unit to a 20 amp branch cir cuit with super lag fuses or equivalent breaker To install the supplied 20 amp plug Connect the white neutral wire under terminal clamp with silver screw and black hot wire under terminal clamp with brass screw Connect green wire under terminal clamp with green screw Tighten terminal wire clamp screws PRO CUT 25 LINCOLN 5 INSTALLATION dl securely WARNING Failure to wire as instructed may cause personal injury or damage to equipment To be installed or checked by an electrician or qualified per son only Use of normal 20 amp household breakers may result in over current trips If breaker trips occur reduce the cutting current output until nuisance trips stop To achieve the full 25 amp output capability of the machine with 115 VAC input remove the 15 amp or 20 amp plug on the input cord and install a 30 amp or 50 amp plug designed for 115 VAC NEMA style 5 30P or 5 50P Follow the instructions included with the plug Connect to an appropriate branch circuit with a mating receptacle The PRO CUT 25 performs best when connected to 230VAC inputs To change over to 230VAC operation install a 230VAC plug with a current rating equal to or greater than 20 amps For us
41. al codes and the manufacturer s rec ommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations LE PLASMA ARC can injure 7 Keep your body away from nozzle and plasma arc 7 b Operate the pilot arc with caution The pilot arc is capable of burning the operator others or even piercing safety clothing ELECTRIC AND MAGNETIC FIELDS 3 may be dangerous 8 a Electric current flowing through any conduc N tor causes localized Electric and Magnetic Fields Qe EMF Cutting or gouging current creates EMF fields around torch cables and cutting machines 8 b EMF fields may interfere with some pace makers so operators having a pacemaker should consult their physician before cutting or gouging 8 c Exposure to EMF fields during cutting or gouging may have other health effects which are now not known 8d All operators should use the following procedures in order to minimize exposure to EMF fields from the cutting or gouging circuit 8 d 1 Route the torch and work cables together Secure them with tape when possible 8 d 2 Never coil the torch cable around your body 8 d 3 Do not place your body between the torch and work cables If the torch cable is on your right side the work cable should also be on your right side 8 d 4 Connect the work cable to the workpiece as close as possible to the area being cut or gouged 8
42. alled immediately put it back in the static shielding 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 Testthe machine to determine if the failure symp tom has been corrected by the replacement PC board NOTE Allow the machine to heat up so that all electrical components can reach their operating temperature 5 Remove the replacement PC board and substitute it with the original PC board to recreate the original problem a If the original problem does not reappear by substituting the original board then the PC board was not the problem Continue to look for bad connections in the control wiring harness junction blocks and termi nal strips b If the original problem is recreated by the substitution of the original board then the PC board was the problem Reinstall the replacement PC board and test the machine 6 Always indicate that this procedure was followed when warranty reports are to be submitted NOTE Following this procedure and writing on the warranty report INSTALLED AND SWITCHED PC BOARDS TO VERIFY PROBLEM will help avoid denial of legitimate PC board warranty claims PRO CUT 25 LINCOLN 5 F 4 Observe Safety Guidelines TROUBLESHOOTING amp REPAIR
43. apabllity cunas an cc i a e d o b e ra a B 4 cue ete ETIN 4 5 Controls and SEIS mir io ep nie B 5 Pilot Arc DISCUSSION ci et re ER RR Rc ani Ed a e e ea Deu a B 6 Procedure Recommendations sise B 7 erc B 7 Suggestions for Extra Utility From the Pro Cut System B 7 PRO CUT 25 LINCOLN 5 OPERATION din SAFETY PRECAUTIONS WARNING e ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground Always wear dry insulating gloves FUMES AND GASES can be dangerous 3 9 AR Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone j WELDING CUTTING and GOUGING SPARKS A can cause fire or explosion Keep flammable material away Do not weld cut or gouge on containers that have held combustibles ARC RAYS 7 can burn A7 Wear eye ear and body protection PLASMA can injure V BE 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 DESCRIPTION The PRO CUT 25 is a constant current conti
44. circuits are electrically hot when the power source is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insu late hands 1 b When the power source is operating voltages in excess of 250 volts are produced This creates the poten tial for serious electrical shock potentially even fatal 1 c Insulate yourself from work and ground using dry insulation When cutting or gouging in damp locations on metal frame work such as floors gratings or scaffolds and when in posi tions such as sitting or lying make certain the insulation is large enough to cover your full area of physical contact with FUMES AND GASES can be dangerous 3 a Plasma cutting or gouging may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When cutting or gouging keep your head out of the fumes Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When cutting or gouging 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 ground Do not use plasma arc cutting or gouging in locations near chl
45. d 5 Do not work next to cutting power source Apr 93 LINCOLN 8 SAFETY PR CAUTIONS DE S RET Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher met allique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonc tionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant
46. de are in place before cutting or gouging The PRO CUT 25 initiates the plasma arc with a simple yet reliable touch start mechanism This system eliminates many of the prob lems associated with hi frequency type start systems INPUT LINE VOLTAGE AND AUXILIARY TRANSFORMER The single phase input power of 115 230 Volts AC is connected to the machine via an input cord to a switch located on the front panel The PRO CUT 25 Input voltage board automatically reconnects the auxiliary and inverter connections to configure the machine for either a low 115V AC or high 230V AC input voltage The auxiliary transformer develops the appropriate AC voltages to operate the cooling fan the control board and the inverter board NOTE Unshaded areas of Block Logic Diagram are the subject of discussion PRO CUT 25 LINCOLN 5 E 3 THEORY OF OPERATION E 3 FIGURE E 3 PRECHARGE AND PROTECTION 3 WORK CLAMP 8 IRG4BC30W D10 Lout BS WRK gt o D Lan Al 2 C26 1 3 24 fe 8A 2 i ALS RL ac 46 8 E spe I T2 300uH R1 a PRI SEC 12VDC TRANSFER I CP Rifle 4 28 e 10 1040
47. e 8 Apply 115VAC input to the PRO CUT 25 machine The test should be performed with 115VAC applied Not 230VAC Note If the peak input voltage is above 400VAC the thermal light may activate Reduce the input voltage Turn on the machine and carefully check for 115VAC 1096 at points A and See Figure F 6 See the Wiring Diagram Note Within 4 seconds of the machine being turned on the two relays RL2 and RL3 should activate If they don t the input board is faulty Figure F 6 Input Board Description TEST POINTS E 4 PLUG PRO CUT 25 LINCOLN 5 dix TROUBLESHOOTING amp REPAIR INPUT BOARD VOLTAGE TEST CONTINUED 10 After the relays activate check for 13 With the torch consumables in place 115VAC from both test points AC to nozzle electrode and shield check CP See Figure F 7 If this voltage is for the presence of approximately not present or low the relay contacts 6VDC at pins 3 and 4 of plug may be defective See Figure F 7 Note With the torch consumables 11 Check the fan voltage at the fan removed this voltage should be terminals V1 amp V2 See Figure F 7 approximately 26VDC Normal is 230VAC If this voltage is normal 230VAC the primary circuit of 14 If the relays RL2 and RL3 are activating the auxiliary transformer is operating with 115VAC applied to the machine correctly and the above test voltages are correct the input board is functioning correctly
48. e consumables and elec trode solenoid are functioning properly MATERIALS NEEDED Volt Ohmmeter 12 VDC 1 Amp Power Supply 7mm Nut Driver 4mm Allen Wrench Crescent Wrench This procedure takes approximately 25 minutes to perform PRO CUT 25 LINCOLN 5 F 25 F 25 TROUBLESHOOTING amp REPAIR TORCH CONTINUITY AND SOLENOID TEST continued FIGURE F 10 LEAD 2 NZL gt WRK gt LEAD 3 EL gt Plug J1 me Harness Plug 0 TEST PROCEDURE 1 Remove input power to the PRO CUT 25 machine Remove carrying handle using a 4mm allen wrench Using a crescent wrench carefully remove the plastic nut from around the pressure regulator located on the top of the machine Using a 7mm nut driver remove the case wraparound Using the ohmmeter 0 y Perform the Capacitor Discharge Remove Plug 1 Lead 2 and Lead 3 from the Main Inverter Board See Figure F 10 check the torch resistances per Table F 1 PRO CUT 25 LINCOLN 5 F 26 TROUBLESHOOTING amp REPAIR F 26 TORCH CONTINUITY AND SOLENOID TEST continued TABLE F 1 TORCH ASSEMBLY RESISTANCES TEST POINTS Lead 2 To Lead 3 CIRCUIT S BEING TESTED Pilot arc leads EXPECTED RESISTANCE 1 5 ohms maximum TEST CONDITIONS Torch consumables in place Lead 2 to Torch Pilot arc lead to 1 0 ohm maximum Torch consumables Nozzle nozzle in place Le
49. e beyond the duty cycle and output rating If excessive operating temperatures should occur the thermal status indicator will turn on and the thermostat will prevent output voltage or current The thermal protection devices are self resetting once the machine cools sufficiently If the 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 is not turning or the air intake louvers are obstructed the input power must be removed and the fan problem or air obstruction must be corrected After a thermal overload occurs and the machine resets it may be necessary to activate the torch trigger twice before a pilot arc will be initiated This is a safety precaution to eliminate accidental pilot arc initiation when the thermal protection self resets ACCIDENTAL OPERATION PROTECTION The PRO CUT 25 has two protection circuits to eliminate accidental pilot arc initiation These two circuits operate when the machine is first turned on and after a thermal overload occurs In these cases the first time the torch trigger is activated nothing will happen The torch trigger must be activated a second time before pilot arc initiation occurs This protection is added in case the machine is turned on and the trig ger is already activated or if a thermal overload self resets and the trigger is activated SAFETY PARTS IN PLACE
50. e circuitry The control board sends a signal to the inverter board to control the output current but the actual regulation circuits are on the inverter board The display board directly connected to the control board communicates PRO CUT 25 status and operating conditions to the user There are four status indicators Power On Gas Pressure Thermal Overload and Safety Error PRO CUT 25 LINCOLN 5 d THEORY OF OPERATION ET PROTECTION CIRCUITS Protection circuits are designed into the PRO CUT 25 machine to sense trouble damages problems with internal components and to provide safety These are the main protection circuits OVERLOAD PROTECTION The PRO CUT 25 is electrically protected from producing higher than normal output currents If the output current exceeds 25 30 amps an electronic protection circuit limits the current to within the capabilities of the machine A second circuit monitors the input voltage and the voltage across the input filter capacitors If the input voltage or filter capacitor voltage is too high or too low the protection circuit will prevent machine output THERMAL PROTECTION Three thermal protection devices protect the machine from excessive operating temperatures One device is located on the output choke one is located inside the main transformer and another is mounted on one of the IGBT heat sinks Excessive temperatures may be caused by a lack of cooling air or by operating the machin
51. e on engine drives keep in mind the above input draw restrictions and the following precaution The PRO CUT 25 can be operated on engine driven generators as long as the 230 volt auxiliary meets the following conditions AC waveform peak voltage is below 400 volts The AC waveform frequency is between 45 and 65 Hz The RMS voltage of the AC waveform is always greater than 208VAC for 115 VAC input divide these values in half The following Lincoln engine drives meet these condi tions when run in the high idle mode Ranger 200 amp 250 engine drives Commander 300 400 amp 500 engine drives Many engine drives do not meet these conditions eg Miller Bobcats etc Operation of the PRO CUT 25 is not recommended on engine drives not conforming to these conditions Such combinations may overvoltage the PRO CUT 25 power source GAS INPUT CONNECTIONS Supply the PRO CUT 25 with clean compressed air or nitrogen e Supply pressure must be between 80 psi and 150 psi Flow rate should be approximately 4 0 cfm 113 l min NOTE Oil in the air supply to the PRO CUT 25 can cause severe problems Use only a clean air supply e Compressed gas be supplied either through the air fitting supplied with the machine or through the 19 BSPP thread the rear of the machine To use the air fitting supplied with the machine packaged in the consumable kit apply teflon tape to the fitting threads a
52. ecifies the appropriate test procedure to verify that the subject component is either good or bad If there are a number of possible components check the components in the order listed to eliminate one possibility at a time until you locate the cause of your problem All of the referenced test procedures referred to in the Troubleshooting Guide are described in detail at the end of this chapter Refer to the Troubleshooting and Repair Table of Contents to locate each specific Test Procedure All of the referred to test points components terminal strips etc can be found on the referenced electrical wiring diagrams and schematics Refer to the Electrical Diagrams Section Table of Contents to locate the appropriate diagram CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD PRO CUT 25 LINCOLN 5 F 2 ES TROUBLESHOOTING amp REPAIR gt PC BOARD TROUBLESHOOTING PROCEDURES ELECTRIC SHOCK cankill 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 prob lems when troubleshooting and
53. ective Carefully apply the 12 VDC supply to the solenoids lower two terminals With proper air pressure applied the solenoid should activate and air should flow from the torch nozzle If the solenoid activates but air does not flow check for a restriction in the air line or torch Reinstall the two leads previously removed PRO CUT 25 LINCOLN Free TROUBLESHOOTING amp REPAIR E29 CONTROL BOARD REMOVAL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing the control board for maintenance or replacement MATERIALS NEEDED Crescent Wrench Small Flathead Screwdriver 7mm Nut Driver 6mm Nut Driver 4mm Allen Wrench 2 5mm Allen Wrench Needle Nose Pliers This procedure takes approximately 30 minutes to perform PRO CUT 25 LINCOLN 5 F 30 TROUBLESHOOTING amp REPAIR CONTRO
54. ectrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing the fan for maintenance or replacement MATERIALS NEEDED 4mm Allen Wrench Crescent Wrench 7mm Nut Driver Phillips Head Screwdriver This procedure takes approximately 12 minutes to perform PRO CUT 25 LINCOLN 5 TROUBLESHOOTING amp REPAIR 44 FAN REMOVAL AND REPLACEMENT continued PROCEDURE 1 Remove input power to PRO CUT 25 4 Using a 7mm nut driver remove the case wraparound 2 Remove carrying handle using a 4mm allen wrench 5 Perform Capacitor Discharge 3 Using a crescent wrench carefully remove the plastic nut from around the 6 Label and remove the two leads pressure regulator located on the top of connected to the top of the fan Be the machine sure to correctly label these leads and note their positions FIGURE F 21 FAN LOCATION PRO CUT 25 LINCOLN 5 F 45 10 11 12 TROUBLESHOOTING amp REPAIR FAN REMOVAL AND REPLACEMENT continued Using a phillips head screwdriver remove the four mounting screws on the four corners
55. emove input power to the PRO CUT 7 Apply the correct input power to the 25 machine Pro Cut 25 machine 115VAC or 230VAC 2 Remove carrying handle using a 4mm allen wrench 8 Carefully test for approximately 300VDC at the P1 bridge terminals See Figure F 8 This represents the rectified voltage supplied from the input board See the Wiring Diagram 3 Using a crescent wrench carefully remove the plastic nut from around the pressure regulator located on the top of the machine 9 Carefully test for approximately 15VAC 4 Using a 7mm nut driver remove the case at the test points on bridge P2 This is wraparound the control supply voltage from the 5 Perform the Capacitor Discharge input board See Figure F 8 See the Procedure detailed earlier in this Wiring Diagram section 10 Carefully test for 12VDC at test points 6 Visually check for burned or damaged C17 See Figure F 8 See Wiring components on the input board If any Diagram This is the rectified and components are physically damaged or regulated DC supply voltage for the determined to be faulty except the inverter board control circuitry fuse the input board should be replaced Figure F 8 Test Points P2 Pi C18 c17 H E O LEAD 2 NZL 4 WRK gt LEAD 3 EL Plug J1 gt Harness Plug RIGHT SIDE OF MACHINE PRO CUT 25 LINCOLN 5 iin TROUBLESHOOTING amp REPAIR diis MAIN INVERTER BOARD VOLTAGE TEST CONTINUED 10
56. en Do Not Over tighten 19 Replace the carry handle Using a 7 mm nut driver replace two leads originating from the Input Switch Reconnect four leads in their correct positions AC and CP PRO CUT 25 LINCOLN 5 F 36 NOTES F 36 PRO CUT 25 LINCOLN 5 iid TROUBLESHOOTING amp REPAIR MAIN INVERTER BOARD REMOVAL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing the MAIN INVERTER BOARD for maintenance or replacement MATERIALS NEEDED 4mm Allen Wrench Crescent Wrench 7mm Nut Driver Needle Nose Pliers This procedure takes approximately 30 minutes to perform PRO CUT 25 LINCOLN 5 Locate the Main Board all associated Label the leads and note their positions Using a 7mm Nut driver remove the four nuts and washers located at the corners of the ma
57. er capacitors for overvoltage If this occurs the appropriate signal is sent to the control board to disable the machines output and to turn on the Thermal Voltage Overload status LED See IGBT Operation discussion and diagrams in this section NOTE Unshaded areas of Block Logic Diagram are the subject of discussion PRO CUT 25 LINCOLN 5 THEORY OF OPERATION FIGURE E 4 MAIN TRANSFORMER Bint WORK CLAMP IRG4BC30W 010 PSN WRK 4 9 coef 5 3 240uH 2 1 E 8A 2 wi Als jac ac E mr 5 reno Lsre bo T2 52 Ri air 5 A 5 PRI sec 12VDC TRANSFER as g 10 10W Bar 5 0114 295 E a E c12 5 zz RL2 CP SL ES ot MIE JB AC Tab ALA R24 vi re 02 8 6 8k 5W TES 1 2 IRG4BC30W zs V SHUNT EL 3 22 his E Ui 2 v 2 SH SH RL1 E a CN2 PT 1 s DI 2 Li 4 2 04 Main Inverter Board Solenoid 2 Input Voltage Board 15161218141 114 137 19242123 8 i 1 2 3 4 TT T Y y 1 M da lt Buell LL 2 ela Ie i Io lt lt I
58. ged 5 a Use only compressed gas cylinders contain ing the correct 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 5 b Always keep cylinders in an upright position securely chained to an undercarriage or fixed support 5 c Oylinders should be located Away from areas where they may be struck or subjected to physical damage A safe distance from plasma cutting or gouging arc weld ing operations and any other source of heat sparks or flame 5 d Never allow any part of the electrode torch or any other elec trically hot parts to touch a cylinder 5 e Keep your head and face away from the cylinder valve outlet when opening the cylinder valve 5 f Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use 5 9 Read and follow the instructions on compressed gas cylin ders associated equipment and CGA publication P I 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 6 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all loc
59. hat Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above 2 b Use suitable clothing including gloves made from durable flame resistant material to protect your skin and that of your helpers from the arc rays 2 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 4 e Vent hollow castings or containers before heating cutting or gouging They may explode 4 f Do nor fuel engine driven equipment near area where plasma cutting or gouging SAFETY 4 g Sparks and spatter are thrown from the plasma arc Wear safe ty 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 goug ing 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 Work cables connected to the build ing framework or other locations away from the cutting or goug ing area increase the possibility of the current passing through lifting chains crane cables or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they CYLINDER may explode if dama
60. in board This will allow you to gently manipulate the board for labeling and removal of all Leads F 38 TROUBLESHOOTING amp REPAIR MAIN INVERTER BOARD REMOVAL amp REPLACEMENT continued FIGURE F 18 MAIN INVERTER BOARD REMOVAL Main Board PROCEDURE 1 Remove input power to PRO CUT 25 6 leads and plug connections 2 Remove carrying handle using a 4mm allen wrench 7 for reassembly 3 Using a crescent wrench carefully remove the plastic nut from 8 around the pressure regulator located on the top of the machine 4 Using a 7mm nut driver remove the case wraparound 5 Perform Capacitor Discharge Procedure CAUTION Be sure to follow the recommended static free methods for printed circuit boards 10 Failure to do so can result in permanent damage to the equipment PRO CUT 25 Remove the two harness plugs from front top corner of board Label and remove the four single leads from the rear top corner of board Carefully remove NZL WRK and EL leads from lower front of board Also remove harness plug 1 See Figure F 19 Remove board LINCOLN 5 F 38 F 39 TROUBLESHOOTING amp REPAIR F 39 MAIN INVERTER BOARD REMOVAL amp REPLACEMENT continued FIGURE F 19 INVERTER BOARD LEAD LOCATIONS Harness plugs NZL gt WRK gt EL E Harness m Plug J1 0 11 Reconnect all leads to the new board 14 Replace the plastic nut from around the pressure regulator D
61. in input power to the PRO CUT 5 Perform the Input Filter Capacitor Discharge 25 Procedure ketailed earlier in this section 2 Remove carrying handle using 4mm allen 6 Visually check for burned or damaged compo IER nents If any components are physically dam 3 Using a crescent wrench carefully remove the aged or determined to be faulty the Main plastic nut from around the pressure Inverter Board should be replaced regulator located on the top of the machine 7 Check the input rectifier bridge P 1 for 4 Using a 7mm nut driver remove the case shorts or opens See Figure F 2 wraparound PRO CUT 25 LINCOLN 5 FI TROUBLESHOOTING amp REPAIR MAIN INVERTER BOARD RESISTANCE TEST continued 8 Check the IGBTs for shorts Check each IGBT 6 from Gate to Collector Normal resistance is approx imately 100 ohms Also check each device from Gate to Emitter Normal resistance is approximately 40 ohms Check each device from Emitter to Collector Normal reading is high resistance in one polarity and a low resistance in the opposite polarity Note These devices will usually fail short resulting in a zero or very low resistance reading If they open physical damage should be evident FIGURE F 3 LOCATION OF IGBTs 6 LEAD 2 NZL WRK gt LEAD 3 EL gt Plug J1 z Harness Plug RIGHT SIDE OF MACHINE PRO CUT 25 LINCOLN 5 gt TROUBLESHOOTING amp REPAIR MAIN INVER
62. ing on equipment Do not touch electrically hot parts Prior to performing preventative maintenance perform the following capacitor discharge procedure to avoid electric shock DISCHARGE PROCEDURE 1 Remove input power to the PRO CUT 25 machine 2 Remove carrying handle using a 4mm allen wrench 3 Using a crescent wrench carefully remove the plastic nut from around the pressure regulator located on the top of the machine 4 Using a 7mm nut driver remove the case wraparound 5 Be careful not to make contact with the capacitor terminals located at the top of the main inverter Board 6 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 7 Locate the eight capacitor terminals located at the top rear of the main inverter board See Figure F 1 8 Use electrically insulated gloves and insulated pli ers 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 9 Repeat the discharge procedure for the other capacitors 10 Check the voltage across the terminals of all capacitors with a DC voltmeter Voltage should be zero If any voltage remains repeat this capacitor discharge procedure FIGURE F 1 LOCATION OF INPUT FILTER CAPACITOR TERMINALS
63. ion which eliminates high frequency emis sions 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 high frequency interference into the Pro Cut can be minimized 1 Make sure the power supply chassis is connected to a good earth ground The work terminal ground does NOT ground the machine frame 2 Keep the work ground clamp isolated from other work clamps that have high frequency 3 If the ground clamp cannot be isolated then keep the clamp as far as possible from other work clamp connections 4 When the machine is enclosed in a metal building several good earth driven electrical grounds around the periphery of the building are recom mended Failure to observe these recommended installation procedures may cause improper function of the Pro Cut or possibly even damage to the control system or power supply components INPUT ELECTRICAL CONNECTIONS The PRO CUT 25 is rated for 115VAC or 230VAC inputs and will automatically reconnect for the supplied voltage The machine is shipped from the factory for operation on 115VAC 15 amp circuits Use on 15 amp branch circuits will limit cutting output as indicated by the graphics around the output knob If the output is set at 20 amps or greater the input fuse or circuit bre
64. k of swirl as the arc exits the nozzle which improves cutting performance No other nozzle has this capability or can match its performance GENERAL OPTIONS ACCESSORIES The following options accessories are available for your PRO CUT 25 from your local Lincoln Distributor 22147 028 VORTECH nozzle with an 028 0 7 mm Orifice 22149 Electrode replacement electrodes for cut ting 22150 Shield Cup This shields the nozzle and pro vides more visibility to the workpiece Note the shield cup does not prevent the torch tip from touching the workpiece K1615 Series PCT 20 Torches come in 15 and 25 lengths Refer to the Parts Pages in the rear of this manual for Torch parts PRO CUT 25 LINCOLN 5 Section D 1 aintenance Input Filter Capacitor Discharge Procedure Routine Maintenance Periodic Maintenance Thermal Protection Replacement Of Internal Fuse Major Component Locations TABLE OF CONTENTS MAINTENANCE PRO CUT 25 LINCOLN 5 Section D 1 i MAINTENANCE pin ELECTRIC SHOCK can kill Have an electrician install and service this equipment Turn the input power off at the fuse box before working on equipment Do not touch electrically hot parts Prior to performing preventative maintenance per form the following capacitor discharge procedure to avoid electric shock INPUT FILTER CAPACITOR DISCHARGE PROCEDURE 1 Remove input power to the PR
65. l and service this equipment Turn the input power off at the fuse box before working on equipment Do not touch electrically hot parts Prior to Performing preventative main tenance perform the following capac itor discharge procedure to avoid elec tric shock ROUTINE MAINTENANCE 1 Keep the cutting or gouging area and the area around the machine clean and free of combustible materials No debris should be allowed to collect which could obstruct air flow to the machine 2 Every 6 months or so the machine should be cleaned with a low pressure airstream Keeping the machine clean will result in cooler operation and higher reliability Be sure to clean these areas See Figure D 2 Printed circuit boards and heat sinks Power switch 3 Examine the sheet metal case for dents or break age 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 continu ity 4 Inspect the cable periodically for any slits or punc ture marks in the cable jacket Replace if neces sary 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 PERIODIC MAINTENANCE WARNING
66. l machines covered by this manual PRO CUT 25 G 5 ELECTRICAL DIAGRAMS G 5 SCHEMATIC CONTROL PRINTED CIRCUIT BOARD SHEET 3 5 4 3 1 Hybrid 2 Hybrid 1 Hybrid 2 Hybrid 1 12V_IN 12V 12V_IN 12V uns es 4 11115 es 4 me tt R200 R201 R206 R211 R212 R217 22k XZ 12 2 2k 2 2k XZ 12 22k D513A DS12A 807 BC807 SZ R18 D512B R40 05138 15k 0200 12 BD438 31 BD438 7 31 24 PRESSURE SW oH R7 SAFETY LO QI 28 2 2k SAFETY LO yg 4 22 49 THERMAL LED 2 3 4 5 6 7 8 9 10 12 13 14 15 16 17 R105 R202 gt R203 gt R204 gt R205 R207 gt R208 R209 gt R210 Hybrid 3 R213 gt R214 gt R215 gt R216 R218 gt R219 gt R220 gt Reel c 2 2k 8e 8e 8e 8e 560 560 560 560 8e 8e 8e 8e 560 560 560 560 5 9 lt 7 118 Display Board 4 ae POWER LED S UG GAS LED S ps THERMAL LED S p SAFETY LED S LDB LDD LDeD LD3B LD3D LD4D LD4C 1068 LDSD 1060 X LD6C LD7B LD7D LD8D LD8C HLMP 2550 HLMP 2550 HLMP 2855 H
67. lectrode and nozzle for maximum elec trode cooling A portion of the cooling air exits in 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 parts in 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 noz zle When the trigger is pulled air flow begins and cre ates 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 output current is estab lished and regulated Once the current stabilizes the solenoid valve turns off removing the forward force on the piston The back pressure drives the piston and electrode away from the nozzle creating the plasma arc The air stream forces the arc out the orifice of the nozzle This appears as a pilot arc which can then be transferred for cutting PRO CUT 25 LINCOLN 5 THEORY OF OPERATION FIGURE E 6 CONTROL BOARD
68. llowing 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 over tighten 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 elec trode is approximately 062 A green and erratic arc will indicate definite electrode failure and 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 turning the power switch OFF and then ON again It is possi ble for electrical noise to trip the safety circuit on rare occasions This should not be a regular occurrence 44 WARNING EN ELECTRIC SHOCK CAN KILL Turn off machine at the disconnect switch on the front of the machine before tightening cleaning or replacing consumables If the machine does not reset or continues to trip consult the Troubleshooting Section Use the proper cutting procedures referred to in Procedure Recommendations PILOT ARC DISCUSSION The PRO
69. lowly 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 The nozzle may be dragged on the metal sur face touching it lightly to the surface NOTE The use of a drag cup with the PRO CUT is not recommended The increased standoff distance reduces the overall performance of the PRO CUT Torch Standoff DRAG thru 1 16 Standoff Where possible start the cut from the edge of the work piece Keep moving A steady speed is necessary Do not pause Suggestions for Extra Utility from the PRO CUT System A WARNING ELECTRIC SHOCK KILL Turn off machine the disconnect switch on the front of the machine before tightening cleaning or replacing consumables help remove any oxide buildup Replace the noz zle turn on the power and continue cutting If the safety circuit continues to trip after cleaning the consumables then replace them with a new set Do not continue to try and cut with excessively worn consumables as this can cause damage to the torch head and will degrade cut quality Do not allow torch cable or body to contact hot surface To improve consumable life here are some sug gestions that may be useful a Make s
70. nd install the fit ting in the port at the rear of the machine NOTE When using nitrogen gas from a cylinder the cylinder must have a pressure regulator Maximum psi from a nitrogen gas cylinder to the PRO CUT 25 regulator should never exceed 150 psi e Install a hose between the nitrogen gas cylinder regulator and the PRO CUT 25 gas inlet 44 WARNING CYLINDER could explode if damaged Keep cylinder upright and chained to a fixed support Keep cylinder away from areas where it could be damaged Never lift machine with cylinder attached Never allow the cutting torch to touch the cylinder Keep cylinder away from live electrical parts e Maximum inlet pressure 150 psi OUTPUT CONNECTIONS Torch The PRO CUT 25 is sent from the factory with a 15 PCT 20 cutting torch installed Additional cutting torch es can be ordered from the K1615 series Hand held torches come with 15 or 25 cables Read and understand this entire section before operat ing the machine PRO CUT 25 LINCOLN 5 Section B 1 Section B 1 TABLE OF CONTENTS OPERATION SECTION Safety PreCautioris aia xa B 2 Description en nn etn ep rb ed eR ee B 2 Preheating Temperature usines B 2 User Responsibility sise eer abad B 3 Operational Features and Controls 3 Design Features and nenne nennen nnne B 3 C tting C
71. ne PRO CUT 25 LINCOLN 5 AS INSTALLATION gt Read entire Installation Section before installing the PRO CUT 25 SAFETY PRECAUTIONS A WARNING ELECTRIC SHOCK CAN KILL Only qualified personnel should install this machine 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 Turn the PRO CUT Power Switch OFF when connecting power cord to input power SELECT PROPER LOCATION Place the PRO CUT 25 where clean cool air can freely circulate in and out the side louvers 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 temper atures and nuisance shutdown of the machine A source of clean dry air or nitrogen must be supplied to the PRO CUT 25 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 approximate ly 4 0 cfm 113 Failure to observe these pre cautions could result in excessive operating tempera tures or damage to the torch STACKING The PRO CUT 25 cannot be stacked TILTING The PRO CUT 25 must be placed on a stable level surface so it will not topple over HIGH FREQUENCY INTERFERENCE PROTECTION The PRO CUT 25 employs a touch start mechanism for arc initiat
72. ng Diagram Input Voltage Perform the CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed 1 800 833 9353 WELD PRO CUT 25 LINCOLN 5 F 8 Observe Safety Guidelines TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE detailed in the beginning of this manual PROBLEMS SYMPTOMS The Thermal LED is lit after normal use POSSIBLE AREAS OF MISADJ USTMENT S LED FUNCTION PROBLEMS 1 One of the machine s thermal protection circuits has tripped Do turn the PRO CUT 25 off Allow the machine to cool The thermal protection circuits will reset themselves Either the duty cycle has been exceeded the fan is not func tioning or the louvers are blocked F 8 RECOMMENDED COURSE OF ACTION 1 Check all connectors and wires for loose or faulty connections See Wiring Diagram 2 The inverter board may be faulty Replace 3 The control board may be faulty Replace CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD PRO CUT 25 LINCOLN 5 F 9 TROUBLESHOOTING amp REPAIR INPUT FILTER CAPACIT
73. ng or gouging can easily go through small cracks and openings to adjacent areas Avoid cutting or gouging near hydraulic lines Have a fire extinguisher readily available 1 i Operate the pilot arc with caution The pilot arc is capable of burning the operator others or even piercing safety clothing 1 j Also see Items 4c and 6 4 b Where compressed gases are to be used at the job site spe cial precautions should be used to prevent hazardous situa tions Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used ARC RAYS can burn 2 a Use safety glasses and a shield with the prop er filter and cover plates to protect your eyes from 4 c When not cutting or gouging make certain no part of the elec sparks and the rays of the arc when performing or trode circuit is touching the work or ground Accidental contact observing plasma arc cutting or gouging can cause overheating and create a fire hazard Glasses headshield and filter lens should conform to ANSI Z87 standards 4 d Do not cut or gouge tanks drums or containers until the prop er 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 T
74. ntrol Board 7 Tze Document Number ev lt 7 125 50 99039 0 lo ter Tuesday Apri 13 1999 heet T OF 3 5 4 3 e 1 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual PRO CUT 25 G 4 ELECTRICAL DIAGRAMS G 4 SCHEMATIC CONTROL PRINTED CIRCUIT BOARD SHEET 2 5 4 3 2 1 8V Ree 8V 8V A 8V 4 A 100k Ate A D500A Res rt R93 255 1 PILDT TIME Boe GAS ENABLE 18k D500B SU ws n R95 3 OMAX OCV TIME 13 U4F R91 43 4 OTG SW 2 42 je HIGH DPEN ze cu U4A D9 DSOSA a IL 0106 560 R22 CF7 R89 1 i D gp O PRESSURE SW ik 25038 D 0106 psbea D502A c9 R24 U4D si T M re SAFETY LD Y 4 17 46 PREFLOW 05 s LM324D LOW PREFLOW 470n 1k 6106 QUSE R23 A OMAX DCV TIME R90 R92 gt R94 1k 10k 15678 10k 270k 10k 6 c10 D5028 q Du MAX PILOT TIME ion 25658 4 4 4 4 125 50 HI 0 PURGE sw 1 25 50 n5668 v TRIGGER DISABLE TRIGGER INTERFACE PREFLOW TIMER L Di O 0 060 8 8V 8V A A 71 R86 R52 10k PIP DETECT 48V R50 0 A 25 yes RESTRIKE Een 2
75. nuous control plasma cutting power source It provides supe rior and reliable starting characteristics cutting visibili ty and arc stability 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 25 comes standard with an air regula tor and pressure gauge The machine also comes with an input power cord Hand held torches are available in 15 or 25 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 The PRO CUT 25 initiates the plasma arc with a sim ple yet reliable touch start mechanism This system eliminates many of the failure problems associated with hi frequency start systems 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 pre vailing codes alloy level and other considerations may also require preheat temperature control The following minimum preheat temperature is recommended as a starting point Higher temperatures may be used as required by the job conditions and or prevailing codes If cracking or excessive hardness occu
76. ny reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD PRO CUT 25 LINCOLN 5 F 5 PROBLEMS SYMPTOMS The machine powers up properly but there is no response no air flow or pilot arc when the torch trigger is pulled Only the power LED is lit The machine powers up properly but only air flows when the torch trigger is pulled no pilot arc is established TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE F 5 Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJ USTMENT S FUNCTION PROBLEMS Make sure the torch handle or cable is not damaged or pulled from the machine Replace if necessary Make sure the air supply is converted and operating properly Make sure the torch consum ables are in place and in good condition Replace if neces sary Set air pressure at 65psi Make sure there are no kinks or restrictions for air flow in the torch cable RECOMMENDED COURSE OF ACTION 1 Check all connectors and wires for loose or faulty connections See Wiring Diagram Perform thelAir Gas The control board may be faulty Replace Check all connectors and wires for loose or faulty connections See Wiring Diagram Perform the Torch Continuity and Solenoid
77. o Not Over 12 Replace the four bolts and washers tighten previously removed from the corners of the board 15 Replace the carry handle 13 Replace the case wraparound PRO CUT 25 LINCOLN 5 F 40 NOTES 90 PRO CUT 25 LINCOLN 5 FS TROUBLESHOOTING amp REPAIR EM SWITCH REMOVAL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing the SWITCH for maintenance or replacement MATERIALS NEEDED 4 mm Allen Wrench Crescent Wrench 7 mm Nut Driver Phillips Head Screwdriver Flat Head Screwdriver This procedure takes approximately 25 minutes to perform PRO CUT 25 LINCOLN 5 TROUBLESHOOTING amp REPAIR F 42 REMOVAL AND REPLACEMENT continued Carefully remove the power switch assembly from the front of the machine making note of insulation p
78. of the fan The fan will become free After replacement of the fan replace the four mounting screws located at the corners of the fan Reconnect labeled leads to the top of the fan Be sure to replace leads in their proper positions Replace the case wraparound Replace the plastic nut from around the pressure regulator Do Not Over tighten Replace the carry handle PRO CUT 25 LINCOLN 5 F 45 TS TROUBLESHOOTING amp REPAIR gt 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 Machine Input and Output 230 1 60HZ 15 Amps 20A 9 10096 Duty Cycle Output Current Range 400 Volts Maximum Open Circuit Voltage Pilot Current Functional Test 1 Connect the machine to 230VAC and an air supply 70psi minimum 2 Turn on the machine and verify the following When the machine is turned on the Thermal LED turns on for approximately 1 second The fan is functional The power LED is lit 3 Testthe pressure switch in the following way Press and hold the Purge button on the front of the machine Using the regulator on the machine slowly lower the air pressure and verify that the gas pressure LED turns on at approximately 35 to 40 psi With the gas pressure LED on release the Purge button and
79. or end of electrode life however the electrode life may last longer A green and erratic arc will indicate definite electrode failure and the electrode should be replaced immediately It is recommended that consumables be replaced in complete sets Example Electrode and Nozzle This will maximize the performance of the PRO CUT system PRO CUT 25 LINCOLN 5 S OPERATION LIMITATIONS Do not exceed output current and duty cycle rating of machine Do not use the PRO CUT 25 for pipe thaw ing CONTROLS AND SETTINGS POWER GAS PRESS THERMAL SAFETY o PRO CUT 25 LINCOLN amp When preparing to cut position the machine as close to the work as possible Make sure you have all mate rials needed to complete the job and have taken all safety precautions It is important to follow these ating steps each time you use the machine Turn the machine s ON OFF POWER SWITCH to 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 LED should turn on Be sure that the work lead is clamped to the work piece before cutting Set the output current control knob at maximum position for higher cutting speed and less dross for mation Reduce the current if desired to reduce the kerf cut width heat affected zone or travel speed as required
80. orinated 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 Gases used for plasma cutting and gouging can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe 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 employ er s safety practices 1 d Always be sure the work cable makes a good electrical con nection with the metal being cut or gouged The connection should be as close as possible to the area being cut or gouged 1 e Ground the work or metal to be cut or gouged to a good elec trical earth ground 1 f Maintain the plasma torch cable and work clamp in good safe operating condition Replace damaged insulation 1 9 Never dip the torch in water for cooling or plasma cut or gouge in or under water 1 h When working above floor level protect yourself from a fall should you get a shock CUTTING SPARKS cause fire or explosion 4 a Remove fire hazards from the plasma cutting or gouging area If this is not possible cover them to prevent the cutting or gouging sparks from starting a fire Remember that welding sparks and hot materials from plasma cutti
81. ositioning Carefully label and identify the four leads and their terminals before removing These leads and their positions are not labeled for you so be sure to label them accurately After labeling the four leads remove them from the switch using a flathead screwdriver After replacement of the switch reconnect the four leads making sure that the switch is oriented correctly and the insulation is positioned correctly Replace the case wraparound Replace the plastic nut from around the pressure regulator Do Not Over tighten Replace the carry handle F 42 SWITCH FIGURE F 20 SWITCH Switch PROCEDURE 1 Remove input power to PRO CUT 25 7 2 Remove carrying handle using a 4mm allen wrench 8 3 Using a crescent wrench carefully remove the plastic nut from around the pressure regulator located on the top of the machine 8 4 Using a 7mm nut driver remove the case wraparound 10 5 Perform Capacitor Discharge 6 Using a phillips head screwdriver remove the two power switch mounting screws 11 located directly above and below the 15 power switch 13 PRO CUT 25 LINCOLN 5 F 43 TROUBLESHOOTING amp REPAIR F 43 FAN REMOVAL AND REPLACEMENT 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 el
82. ovoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de levage c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants 11 Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 PR CAUTIONS DE S RET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR 1 Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise
83. pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie du corps Un coup d arc peut tre plus s v re qu un coup de soliel donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du rayon nement de l arc et des projections quand on soude ou quand on regarde l arc b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc c Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones l on pique le laitier 6 Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut pr
84. r manent damage to the equipment 10 removal GENTLY pull the case front forward and carefully remove the Control board 13 Replace the Control Board by GENTLY pulling the 1 1 nut 2 pe 2 case front forward and carefully sliding the This wil AIME ien er Control board back into its original position Reconnect plug and lead assembly forward so the Control board can be removed p ug y See Figure F 15 14 Replace the four allen mounting screws Remove the Four allen bolts with a 2 5 mm allen 15 Replace the screws connecting the case front to wrench the central metal wall PRO CUT 25 LINCOLN 5 F 32 TROUBLESHOOTING amp REPAIR F 32 CONTROL BOARD REMOVAL AND REPLACEMENT continued 16 Replace the red PURGE button 17 Replace the plastic OUTPUT knob align it in its original position and tighten nut 18 Replace the red cap on the end of the OUTPUT knob 19 Replace the case wraparound 20 Replace the plastic nut from around the pressure regulator Do Not Over tighten 21 Replace the carry handle PRO CUT 25 LINCOLN 5 F 33 TROUBLESHOOTING amp REPAIR F 33 INPUT BOARD REMOVAL AND REPLACEMENT 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 ob
85. regulated via pulse width modulation The control circuitry on the inverter board receives a signal from the control board and regulates the output current to the desired level PRO CUT 25 LINCOLN 5 E 5 THEORY OF OPERATION E 5 FIGURE E 5 PLASMA OUTPUT SECTION AND TORCH 3 GE WORK CLAMP a IRG4BC30W 010 Lout 78517 WRK vr 2 6 4 3 240uH B 1 a BA S L1 RL3 E BAL 7 T2 52 On gt Bi EXPL al 26 E PRI SEC 12VDC TRANSFER ES 10 10 E ter CP A 5 tab SE 1 DIA ALI gt E o 4 5 gt RL2 CP o re Eh a 7 lt AG ach je cia E R24 vil RL2 Q2a b c 6 8k 5W 9 MENA 8 IRG4BC30W E H ES Lt SHUNT EL 3 m hs E 236 n v 7 230V SH SH Z E 115 1 57 2 E 4 2100 Main Inverter Board Solenoid 2 Input Voltage Board 16121814 1 114 137 192421238 1 1 2 3 4 M T d m a lo lo Lo e e fos ISIE RIS 8 lt Sigs lt lo lo lo E 15 2 SES o 7 lt lt b
86. replacing PC boards please use the following procedure 1 Determine to the best of your technical ability that the PC board is the most likely component caus ing the failure symptom 2 Check for loose connections at the PC board to assure that the PC board is properly connected 3 If the problem persists replace the suspect PC board using standard practices to avoid static electrical damage and electrical shock Read the warning inside the static resistant bag and perform the following procedures PC Board can be damaged by static electricity Remove your body s static charge before opening the static shielding bag Wear an anti sta tic wrist strap For safety use a Aa ATTENTION D Static Sensitive 1 Meg ohm resistive cord con Devices nected to a grounded part of the Handle only at equipment frame See If you don t have a wrist strap Workstations touch unpainted grounded part of the equipment frame Reusable Keep touching the frame to Container prevent static build up Be sure not to touch any electrically live parts at the same time Do Not Destroy Tools which come in contact with the PC Board must be either conductive anti static or static dissipative Remove the PC Board from the static shielding bag and place it directly into the equipment Don t set the PC Board on or near paper plastic or cloth which could have a static charge If the PC Board can t be inst
87. rs on the cut face higher preheat temperature may be required The rec ommended minimum preheat temperature for plate thickness up to 1 2 12 7mm is 70 F 21 1 PRO CUT 25 LINCOLN 5 B 3 USER RESPONSIBILITY Because design fabrication erection and cutting vari ables affect the results obtained in applying this type of information 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 than those expected Some adjustments to procedures may be necessary to compensate for unique individual conditions Test all procedures duplicating actual field conditions OPERATIONAL FEATURES AND CONTROLS The PRO CUT 25 comes with an ON OFF POWER SWITCH OUTPUT CURRENT CONTROL and PURGE BUTTON DESIGN FEATURES AND ADVANTAGES The PRO CUT 25 design makes plasma cutting uncomplicated This list of design features and advan tages 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 OPERATION B 3 Continuous control 12 25 amps Reliable touch start mechanism for plasma arc initia tion Rapid arc restrike for fast cutting of expanded metal Input over voltage protection Bright 3 0 second timed pilot arc
88. s 5 lt 5l l2 gt e 5 OP Im 2 2 ES 15 14 0 m E SB 51 een SIS lt y y 4 4 8 6179 3 1 21814 7 15 4 115 16101213 23222 9 Jo L J 12VDC 1 Display LED s 1 Solenoid Switch 1 Control Board Output Control MAIN TRANSFORMER The pair of IGBTs act as a switch assembly This assembly feeds a primary winding of the main trans former When current is pulsed through this primary winding a resultant current is produced on the sec ondary winding of the main transformer The DC cur rent flow through the primary winding is redirected or clamped back to the filter capacitors when the IGBTs are turned off This is needed due to the inductance of the transformer primary winding The primary current also passes through the current transformer which sends a signal to the control cir cuits of the inverter board This signal and the control circuits limit the maximum primary current flow through the IGBTs The pair of IGBT s are fired at 15 microsecond intervals creating a constant 66 6KHz output The secondary portion of the main transformer is made up of one winding This winding supplies the electrode to nozzle and electrode to work voltages and the resulting currents This high current winding is capable of supplying maximum output current during the cutting process The output current is
89. sent This is similar to turning ON a light switch FIGURE E 5 IGBT BODY REGION lt DRAIN DRIFT REGION BUFFER LAYER n p lt INJECTING LAYER DRAIN A PASSIVE POSITIVE VOLTAGE loc O GATE BODY REGION lt DRAIN DRIFT REGION BUFFER LAYER INJECTING LAYER B ACTIVE PRO CUT 25 LINCOLN 5 Section F 1 TABLE OF CONTENTS TROUBLESHOOTING amp REPAIR SECTION Troubleshooting Repair Section Section F How to Use Troubleshooting Guide F 2 PC Board Troubleshooting Procedures and Replacement F 3 Troubleshooting ete ees F 4 Test Procedures Input Filter Capacitor Discharge Procedure UV F 9 Main Inverter Board Resistance F 11 Input Board Voltage Test F 17 Main Inverter Board Voltage Test F 21 Torch Continuity and Solenoid Test F 24 Air Gas Solenoid Testament nm e e IE F 27 Replacement Procedures Control Board Removal and Replacement eem F 29 Input Board Removal and eem F 33 Main Inverter Board Removal and Replacement F 37 Switch Removal and Replacement eene F 41 Fan Removal and su F 43 Retest sci tae tote mte deed D bed tern Den e Le e prev ee ead tl F 46 PRO CUT 25 LIN
90. serve all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call or 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing the input board for maintenance or replacement MATERIALS NEEDED 4 mm Allen Wrench Crescent Wrench 7 mm Nut Driver Needle Nose Pliers This procedure takes approximately 25 minutes to perform PRO CUT 25 LINCOLN 5 F 34 TROUBLESHOOTING amp REPAIR F 34 INPUT BOARD REMOVAL amp REPLACEMENT continued FIGURE F 16 Input Board Location Input Board PROCEDURE 1 Remove input power to PRO CUT 25 6 Note the orientation of the input board to avoid confusion during 2 Remove carrying handle using a reassembly 4mm allen wrench 7 Carefully label and remove cooling fan 3 Using a crescent wrench carefully leads from Input Board Pliers may be remove the plastic nut from around the necessary pressure regulator located on the top of the machine 8 Remove harness plug from lower right hand corner of board Pliers may be 4 Using a 7mm nut driver remove necessary the case wraparound 9 Directly above the harness in step 8 5 Perform Capacitor Discharge Procedure there are four leads CP 2 and ACQ Label these leads and
91. the arc will transfer the current will ramp to the setting on the control panel and the cut can last indefinitely or until the duty cycle of the Pro Cut is exceeded Pierce the work piece 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 30 ANGLE TO PIERCE ROTATE TO 90 ANGLE TO CUT FOR CUTTING Keep moving while cutting Cut at a steady speed without pausing Maintain the cutting speed so that the arc leg is 10 to 20 behind the travel direction PRO CUT 25 LINCOLN 5 ES OPERATION ES 5 15 Leading Angle gt gt Direction of Travel i 10 Arc Lag Use a 5 15 leading angle in the direction of the cut 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 f 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 frequently If the SAFETY LED lights at any time check the fo
92. then pull the trigger on the torch Verify that a pilot arc does NOT occur Release the trigger While again pressing the Purge button slowly increase the air pressure using the regulator on the machine until the gas pressure LED turns off Verify that the LED turns off at approximately 40 45 psi Continue to press the Purge button and set the air pressure at 65psi Release the Purge button gt Test the Purge button safety function by again pressing the Purge button and then pulling the trigger on the torch Verify that a pilot arc does NOT occur Release the trigger and the Purge button This is nota repeat of the previous step in this step the Purge button is pressed and the gas pressure LED is off et With no air flowing postflow pull the trigger on the torch Verify that the air flows for 2 seconds preflow and then the pilot arc is initiated While continuing to hold the trigger verify that the pilot arc remains lit for 3 seconds then turns off automatically Release the trigger and verify that the air continues to flow for 10 seconds postflow Remove the shield cup from the torch and verify that the safety LED turns on Re tighten the shield cup on the torch and verify that the safety LED remains lit Pull the trigger of the torch and verify that a pilot arc does NOT occur Turn the machine off and then back on to clear the safety error Turn the PRO CUT 25 off o T4 PRO CUT 25 LINCOLN 5 F 47 N OTE S F 47 P
93. tly to the work piece Make sure the torch consum able parts are in place and in good condition Replace if necessary Make sure the air pressure is set at 65psi Make sure the air supply is not contaminated with oil or excessive water TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE F 6 RECOMMENDED COURSE OF ACTION Perform the Check all connectors and wires for loose or faulty con nections See Wiring Diagram Perform the Torch Continui and Solenoid Test Main Inverter Board Voltage Tests The control board may be faulty Replace The pilot arc is normal but the arc will not transfer to the work piece Make sure the operating procedure is correct for the process See the section lof the manual Make sure the work clamp is connected tightly to the work piece The work piece must be electri cally conductive material and the work clamp must make a good electrical connection with the work piece 2 Check all connectors and wires for loose or faulty con nections See Wiring Diagram Perform the Main Inverter Board Voltage land 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 con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD P
94. tric This information is pro vided 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 LIN LN 3 ine LINCOLN macane PRO CUT 25 SVM ERROR REPORTING FORM We need to know if there are errors in our manuals We also value any suggestions as to additional tests or procedures that would make this SVM a better tool for you If you discover new or different Problems or Symptoms that are not covered in the three col umn troubleshooting chart please share this information with us Please include the machine s code number and how the problem was resolved Thank You Technical Services Group Lincoln Electric Co 22801 ST Clair Ave Cleveland Ohio 44117 1199 FAX 216 481 2309 SVM Number Page Number if necessary Your Company Your Name Please give detailed description below SD287 01 99 LINCOLN P
95. u jn 2mg mm E gt 55 Ko lo lo EE 8 6179 3 1 2 1814 7 15 4 11 5 16101213 23222 fo fe CNT jo 12VDC 1 A Display LED s Ir Purge Solenoid Switch 1 Control Board Output Control OUTPUT SECTION AND TORCH The output section contains a relay which upon receiving a pilot signal from the control board will enable the operation of a pilot arc or a cutting arc The printed circuit board mounted current sensor regulates the pilot and cutting current The output choke which is in series with both the pilot circuit and the cutting circuit provides current filtering to enhance arc stabil ity The PCT 20 torch uses a patented touch start mecha nism 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 dri vesthe 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 e
96. ure the air supply to the Pro Cut is clean and free of oil Use several extra in line filters if necessary b Minimize dross buildup on the nozzle tip by starting the cut from the edge of the plate when possible c Pierce cutting should be done only when nec essary If piercing angle torch about 30 from the plane perpendicular to the work piece transfer the arc then bring the torch perpen dicular to the work and begin parallel move ment d Reduce the number of pilot arc starts without transferring to the work e Reduce the pilot arc time before transferring to the work f 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 g Use only Lincoln consumable parts These parts are patented and using any other replacement consumables may cause damage to the torch or reduce cut quality PRO CUT 25 LINCOLN 5 B 8 NOTES PRO CUT 25 LINCOLN 5 B 8 Section C 1 Section C 1 TABLE OF CONTENTS ACCESSORIES Accessories a rre p he e peso es a as Section C Optiohns Accessorles DER RI ER OD ee erga dide de abl s C 2 PRO CUT 25 LINCOLN 5 ACCESSORIES ve ALWAYS USE GENUINE LINCOLN ELECTRIC ELECTRODES AND VORTECH NOZZLES Only Genuine Lincoln Electric consumables yield the best cutting performance for the PRO CUT 25 The patented VORTECH nozzle provides an extra kic

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