Home

Lincoln Electric SVM104-A User's Manual

1. 1 2 5 c Oo o gt 9 24 D D o 184 o ee Soo PHS at 7 SPARE QUTPUT INPUT PORT gt 8 Ax TQ s i E c c 50 ps ja es Z wo Q RR RAR A Kg 52 A s 2548 25252 als i ua hs usus S s ls fe 2 4OUTPUT o ac E E n R 4 h Q 5 o e 92 o 4 ta jj Em ap ak 5e gt UM oS 2727 Tes Pa c S 969 uv z foo o E ioe Sas o g Pos 184936 PR te voc PB TREE D d 2 v o e e 1 lt vss PBO n 4 20 pei 10K Q o 9 n 856 1w 06870583 sm A E 2 5 gt 5 5 Q sd m aes v m TO SHUNT S G e e 2 FAULT o V Em gt mut 8 t Yoz 5 Q E o o 2 9 2g e o RIS o D CONTROL PO
2. NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is provided for reference only Lincoln Electric dis courages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine PRO CUT 60 LINCOLN amp Return to Section TOC Return to Master TOC Return to Section Return to Master TOC Return to Section TOC FE 5 nile Bs EJE Bi oO wv iac Return to Section TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G 7 CONTROL BOARD Item Identification Item Identification IC NMOS MCU 68705R3CS R3 R8 R14 R20 R21 R35 R36 RESISTOR MF 1 4W 10 0K 1 5 IC CMOS GATE NAND 2 INPUT QUAD 4011 R40 R41 R43 R44 R81 R82 a IC CMOS INVERTER SCHMITT HEX 4584 R94 R95 R96 R97 R98 R103 CAPACITOR CEMO 22P 100V 5 R104 R111 R123 R
3. Return to Section TOC Return to Master TOC lu nile 818 EJE gt 21 iac L7941 POWER BOARD NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is provided for reference only Lincoln Electric dis courages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine Return to Section TOC Return to Master TOC PRO CUT 60 LINCOLN Return to Section Return to Master TOC Return to Section TOC FE 5 TER BIS EJE Bi iac Return to Section TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS Identification tied A TRANSISTOR HEAT SINK ASBLY 0047 400 10 RT ee nts IC CMOS INVERTER SCHMITT HEX 4584 11 12 19
4. vje C506 460 575V 208 230 460V 52 E io TOME MAIN TRANSFORMER 1 J 2 5 3000V 389 ELECTRICAL CODE I Beth CR2 GENERAL INFORMATION HE TO SUPPLY LINES ELECTRICAL SYMBOLS PER E1537 cH g 0 LI se RESISTORS OHM WATT 1 2 WATT UNLESS ol 50w OTHERWISE SPECIFIED C CAPACITORS MFD VOLTS oe p40 22 AUXILIARY COLS NUMBER 3 IS CONNECTED TO THE NOZZLE et H3 H4 12 VAC PILOT LEAD AT THE TORCH 120 power POS H6 C2 24 VAC 6 7 amp 8 APPEAR ON TRIPLE VOLTAGE E EL TO GROUND 31 32 115 VAC amp 208V SINGLE MACHINES ONLY PER NATIONAL C1 32 24 VAC WORK ELECTRICAL CODE 4 8 94D CLEVELAND OHIO U S A L9610 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual The Return to Master TOC specific diagram for a particular code is pasted inside the machine on one of the enclosure panels LINCOLN PRO CUT 60 Return to Section TOC Return to Section TOC Return to Master TOC Return to Section TOC 15 3 12 3 cle y vio ojo Return to Section TOC Return to Master TOC Return to Master TOC LINCOLN ELECTRICAL DIAGRAMS WIRING DIAGRAM FOR CODES 9819 10096 TO SUPPLY LINES G 17 TO SUPPLY LINES OUTPUT CONTROL 53 cw o 51 TO
5. 3 nile 818 EJE Bi iac CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216 383 2531 or 1 800 833 9353 PRO CUT 60 Return to Section TOC Return to Master TOC 9 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION FUNCTION PROBLEMS Airflow does not shut off 1 Remove input power to the 1 Remove leads 38 and PRO CUT 60 If the air con 31 plug J12 from air tinues to flow the air solenoid solenoid SV1 Refer to SV1 could be jammed or wiring diagram stuck open a If air continues to flow the solenoid is faulty If air pressure is above Replace 125 PSI solenoid may be b If the airflow stops when damaged Set for 60 65 PSI the solenoid SV1 leads are removed then the Control Board could be Return to Section TOC Return to Master TOC The OUTPUT ON and AIR Turn power off then restart The Control Board could PRESSURE LED s blink in machine be faulty Replace alternating order Return to Section TOC Return to Master TOC nile 818 EJE Bi WV iac CAUTION If for any
6. aie Section Safety PreCaulons MM D 1 9 Capacitor Discharge 8 0 1 0 2 Routine and Periodic Maintenance D 3 CDE m D 4 Return to Master TOC Q 0 4 gt 4 c 5 Return to Master PRO CUT 60 Return to Section Return to Master TOC Return to Section TOC nile 818 EJE Bi o iac Return to Section TOC Return to Master TOC Return to Master TOC PRO CUT 60 MAINTENANCE SAFETY PRECAUTIONS A WARNING ELECTRIC SHOCK can kill Only qualified personnel should perform this mainte nance Turn the input power OFF at the disconnect switch or fuse box before working on this equipment Failure to follow this capaci tor discharge procedure can result in electric shock Do not touch electrically hot parts CAPACITOR DISCHARGE PROCEDURE PROCEDURE DESCRIPTION This procedure must be performed before per forming any maintenance inside the machine MATERIALS NEEDED High resistance high wattage resistor 25 1000 ohms 25 watts minimum Insulated pliers Insulated gloves DC Volt Ohm meter Multimeter LINCOLN amp ELECTRIC Return to Section Return to Master TOC Return to Section TOC Return to Master TOC FE
7. Return to Master WELDING CUTTING and GOUGING SPARKS can cause fire or explosion z Keep flammable material away Qio Ojo E Do not weld cut or gouge on 8 containers that have held combustibles o gt ARC RAYS 8 8 can burn 2 4 5 5 117 g 9 Wear eye ear and body a protection PLASMA ARC can injure V Keep your body away from nozzle ME and plasma arc Operate the pilot arc with caution The pilot arc is capable of burning the operator others or even piercing safety clothing Observe additional Safety Guidelines detailed in the beginning of this manual PRO CUT 60 Return to Section TOC Return to Master TOC Return to Section Return to Master TOC Return to Section TOC Return to Master TOC FE a nile 818 EJE Bi ic Return to Section TOC Return to Master TOC OPERATION GENERAL DESCRIPTION The PRO CUT 60 is a constant current single range continuous control plasma cutting system The microprocessor based PRO CUT 60 is capa ble of cutting with compressed air or nitrogen gas Nitrogen gas is used to cut aluminum or other non ferrous metals This sophisticated system has excellent starting characteristics cutting visibility and arc stability The machine automatically per forms fundamental troubleshooting when turned ON The PRO CUT 60 is equipped with a patented plasma torch that has
8. damaged 5 a Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Cylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication 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 lo
9. 2 DOL ISe W uinjeu DOL J893se A DOL 4 1 DOL JSE W DOL gt 5 03 DOL uonoes 03 uum DOL uonoes 03 DOL uonoes G 6 ELECTRICAL DIAGRAMS CONTROL BOARD PRO CUT 60 SINGLE PHASE Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC O AE nile 8 8 EJE gt 21 aic
10. CAPACITOR CEMO 022 50V 20 C15 C16 C17 C18 CAPACITOR CEMO 820P 50V 5 420 22 CONNECTOR MOLEX MINI PCB 4 PIN DOM M TP CONNECTOR MOLEX MINI PCB 6 PIN D1 D2 D7 sra e DIODE AXLDS 1A 400V R13 R14 R15 R16 RESISTOR CC 2W 27 10 Filo c uu RESISTOR WW 5W 40 5 SQ R11 R18 RESISTOR WW 15W 2 5K 5 SQ CAPACITOR ALEL 50 50V 75 10 ee ee CAPACITOR PCF 27 50V 20 Cl bead tage eae CAPACITOR ALEL 3300 50V 30 10 OPTOCOUPLER PHOTO Q 70V CNY17 3 G3 CTS CAPACITOR PEF 0 1 100V 10 C6 C7 C8 C9 C10 C20 CAPACITOR PEF 0 22 400V 10 CHOKE RF 390UH 10 1A SLEEVED one gees ee ZENER DIODE 1W 27V 10 1N4750A 074 075 076 ZENER DIODE 1W 15V 5 1N4744A DZ1 DZ2 DZ3 ZENER DIODE 1W 6 2V 5 1N4735A 2 525 25 22 ded ada TRANSISTOR NMF T220 3 5A 60V IRF513 D3 D4 D5 D6 DIODE AXLDS 3A 600V 1N5406 RESISTOR CC 2W 120 5 MOV 320VRMS 160J 20MM 4 21 323 RESISTOR MF 1 4W 1 00K 1 RESISTOR MF 1 4W 10 0K 196 R22 MEE RESISTOR MF 1 4W 150 1 H5 H6 E RESISTOR MF 1 4W 2 00K 196 R19 R20 RESISTOR MF 1 4W 20 0 196 crc RESISTOR MF 1 4W 26 7 196 Base teas RESISTOR MF 1 4W 4 75K 196 Sets es fat le RESISTOR MF 1 4W 47 5K 196
11. DIODE AXLDS 1A 400V FR 1N4936 CAPACITOR CEMO 100P 100V 5 CAPACITOR CEMO 4700P 50V 2 ea es ee DIODE AXLDS 3A 600V FR 856 B1 B2 B3 B4 B5 B6 B7 B8 B9 EYELET R10 R24 R25 R26 RESISTOR WW 10W 7 5 596 G 9 POWER BOARD NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is provided for reference only Lincoln Electric dis courages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine LINCOLN amp PRO CUT 60 G 10 ELECTRICAL DIAGRAMS STATUS PC BOARD Return to Section TOC Return to Master TOC PROCUT 60 M15601 status Return to Section TOC Return to Master TOC CONNECTOR ON BOARD BACK lu nile 818 EJE Bi WV iac NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is provided for reference only Lincoln Electric dis courages board level troubleshooting and repa
12. FE au nile 818 EJE 5 5 Bi o iac Return to Section TOC Return to Master TOC ELECTRICAL DIAGRAMS G 15 BYPASS PC BOARD M17322 Item Identification B71 B72 B389 BGND1 BPOS2 1 4 TAB TERMINAL xg Res 420V 160J 22MFD 400VDC CAPACITOR 10 R1 R2 R3 R4 475K 1 4W 1 e rp JEEP ELE 047 1600 10 CAPACITOR NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is provided for reference only Lincoln Electric dis courages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine LINCOLN 3 PRO CUT 60 ELECTRICAL DIAGRAMS G 16 WIRING DIAGRAM FOR CODES 10112 10118 eio olo e c Bla TO SUPPLY 208 _ TO SUPPLY ole LINES LINES ols i SAFETY OUTPUT eae STATUS BOARD 1 CONTROL I Lof I 19 3 rips 10K 1 515 1 8 I 5 326 we lice ver eee es 325 Md L l Fr 2 5 76 T TS 21219214216 1 TO PRIMARY 211213 216 218 TO GROUND COILS T
13. LINCOLN NOTES PRO CUT 60 D 5 DOL ISe W DOL J893se A DOL 4 1 DOL JSE W uino DOL gt 5 oj DOL uonoes 03 uum DOL uonoes 03 DOL uonoes TABLE OF CONTENTS Section E THEORY OF OPERATION SECTION E 5 Theory of Operation Section 1424 4242 Section E 8 Power Supply Operation secs 1 4 Input Line Voltage and E 1 Output Rectification OD nennen 2 High Voltage High Frequency and By Pass E 3 E e E 4 Transistor Switching ODGTFAllOli enses esa xS bbs OR E 5 PWM Operation and Thermal Protection E 6 TORCH TRIGGER amp OUTPUT SAFETY CIRCUIT CONTROL STATUS 115 HIGH VOLTAGE BOARD TRANSFORMER FEEDBACK CIRCUIT 115VAC Return to Master TOC AIR SOLENOID CONTROL POWER 115VAC BOARD BOARD CR2 115VAC CY HI FREQ TRANSFORMER LINE SWITCH RECONNECT BY BD CR2 s Q 0 4 gt 4 c LE 5 SCR DIODE TRANSISTOR BRIDGE MODULE FIGURE E 1 Block Logic Diagram Return to Master TOC PRO CUT 60 Return to Section
14. Return to Master TOC Return to Section TOC Return to Master TOC amp c 9 E 9 4 42 ac Return to Section TOC Q O 0 4 gt 4 c 5 5 a Return to Master TOC THEORY OF OPERATION E 6 FIGURE E 8 Pulse Width Modulation DC INPUT SUPPLY OUTPUT BASE DRIVE PULSE WIDTH MODULATION The term PULSE WIDTH MODULATION is used to describe how much of a given time period is devoted to conduction collector current flow Changing the pulse width within a given time peri od is known as MODULATION A PWM THERMAL PROTECTION THERMOSTAT A thermostat protects the machine from excessive operation temperatures Excessive operating temperatures may be caused by a lack of cooling air or operating the machine beyond the duty cycle and output rating If excessive operating temperature should occur the thermostat will dis able the machine output and the yellow thermal indicator light will glow The fan should remain on during this period Once the machine cools suffi ciently the thermostat will reset If the thermostat shutdown is caused by excessive output or duty cycle and the fan is operating normally the power switch may be left on and the reset should occur within a 15 minute period If the fan is not turning or the air intake louvers are obstructed then the input power must be removed and the fan problem or air obstruction be correct ed L
15. rm 9 o E o o 5 amp gt G ie o c 2 c o 5 o iS E pum 5 9 gt gt c c z gt Q c 0 only L LINCOLN amp ELECTRIC 2 c A e Return to Section TOC Return to Master TOC Return to Section TOC 15 3 12 3 cle y vio ojo Return to Section TOC Return to Master TOC Return to Master TOC LINCOLN ELECTRICAL DIAGRAMS G 19 POWER BOARD SCHEMATIC DESIGN 600v 39mH 3A 03 XI Di D A COLLECTOR 25K c5 amp 15W L021 4 15K T E 071 120 5118 4 di 13300 AOV 2w 2 10 c20 J22 CY T c 1W 2 5 22 NN lt 3 lt Di 50V 15W oov amy 0 D 02 AI ANODE 600v 144936 1 d H V 12 HS jJ alts 115 11 NEC O 2K as 5 55 Sjow Slow Dz5 ORTE
16. Return to Master TOC Return to Section TOC Return to Master TOC nile 818 EJE Bi ic Return to Section TOC Return to Master TOC E 1 THEORY OF OPERATION FIGURE E 2 Input Line Voltage and Main Transformer TORCH TRIGGER amp OUTPUT SAFETY CIRCUIT CONTROL STATUS BOARD 115VAC AIR SOLENOID CONTROL 115VAC SCR DIODE BRIDGE INPUT LINE VOLTAGE AND MAIN TRANSFORMER The desired single phase input power is connect ed to the Pro Cut 60 through a line switch located on the front panel of the machine A reconnect panel allows the user to configure the machine for the desired input voltage This AC input voltage is applied to the primary of the main transformer This main transformer changes the input voltage and current to the voltage and cur rent levels necessary for plasma cutting In addi tion the main transformer also has several 115VAC FEEDBACK HIGH VOLTAGE TRANSFORMER CIRCUIT TRANSISTOR MODULE isolated auxiliary windings 115vac 24vac and 12vac The 115vac winding supplies power for the cooling fan and powers the air solenoid the CR2 relay and the high voltage transformer via the control board One 24vac winding produces supply power for the control board The other 24vac winding is applied to the control board and is used in the Pro Cut 60 torch safety and trigger network The 12vac winding is required to oper ate the power board
17. Return to Section He S 5 Return to Master TOC OPERATION 6 Use nozzle with the largest orifice that gives the best cut for the work being done This pro duces the best work results and consumable life As the size of the nozzle orifice increases its current capability increases Therefore the nozzle used for cutting or gouging work must be able to handle the current needed to give the best cutting results A nozzle working beyond its current capability overheats caus ing poor performance Never use the 035 inch 0 8mm nozzle when the current output is above the yellow current range Use the S24114 Drag Cup when the output current is in the red range to protect the torch from dross and the effects of improper arcing conditions NOTE The 24114 Drag Cup should not be used at very low outputs Do not allow your body or the torch cable to touch hot surfaces Refer to the User Chart Range guide on the machine s nameplate for recommended out put current ranges for the thickness of the metal being cut LINCOLN 8 ELECTRIC B 6 Cutting Thin Gauge Sheet Metal 1 Set the OUTPUT CURRENT CONTROL out put at mid range Yellow range or below Pierce a hole in the metal surface to start the cut Then lightly touching the nozzle to the metal surface drag the torch along the cut line Use the 035 0 8mm nozzle for fine cuts Larger nozzle
18. glo Or li D44H7 02 EMITTER L 120 2 0041 D E A 4 15 26 7 L 4 400V C3 M s 100v 08 D o3 MR856 ZX lao aL C2 a 3 5A 600 5w ps 600 072 7 29 464 x n6 60V q 3A 6 2V 50V 12 lt IRF513 aE C16 J2 100p L 4 T 100v 026 79 ZR E T 3A V 10K E 1w 07 A 400V D6 600V bs V c 1 22 22 C6 400v CT 400v Gl IX Ji J21 J2 J22 073 1 006 lt 5 gt 3 lt 2 a u m 2W e2V 5 um T H E 27 LOOK 018 lt i lt 124 gt CNYIT 3 lt SEIEN _ 6 4 DZ4 ZEE a a J22 15 ae J R22 1w 77 220 ci H2 K2 150 C21 za 0 4 o zl HMT 5K 75 22 0047 Z 2 400V 00V 50V lt 420 Se 4 7 ES ind 21 21 TEL 3 2 94 Sw W MJH 4 29 92 WRS 3 6 92 320V WRS 2 12 92 00 WRS 1 30 92 MCW 7 2 91 MJH 9 13 90 GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 CAPACITORS 022 50V UNLESS OTHERWISE SPECIFIED RESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED DIODES 1A 400V UNLESS OTHERWISE SPECIFIED 12 SUPPLY VOLTAGE NET O POWER SUPPLY SOURCE POINT 4 lt E NOTES pe 73 c19 T m N A SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE COMMON CONNECTION a amp reefs ELT St we F1 cave HEXTRGR NUMBER
19. present STOP Perform 3 Disconnect and remove the torch cable assembly from the again If no voltage is bulkhead compartment present continue X test procedure a Locate the torch cable access door on the Right Case Side Assembly of the machine PRO CUT 60 Return to Section TOC Return to Master TOC Return to Section Return to Master TOC Return to Section TOC Return to Master TOC 9 AM o n 9 HM oc Return to Section TOC Q O H f 0 41 gt 5 Return to Master F 51 PRO CUT 60 TROUBLESHOOTING amp REPAIR TORCH HEAD REMOVAL REPLACEMENT d Disconnect the trigger lead 4 pin connector by unscrewing it e Disconnect the electrode lead using a 9 16 open end wrench to remove the brass adaptor fitting attached to the bulkhead connector f Disconnect the pilot lead by removing the wing nut marked PILOT Remove only the pilot lead Do not remove any of the leads below the brass nut g Detach strain relief clamp wrapped around the trigger lead electrode lead and pilot lead from the bolt to which the strain relief clamp is attached Do not remove the strain relief clamp from around the three leads h Pull the trigger lead electrode lead and pilot lead bundled in the strain relief clamp out of the machine through the rubber boot Move the torch cable assembly to a convenient work
20. et xen CONNECTOR MOLEX MINI PCB 10 PIN JO exa CONNECTOR MOLEX MINI PCB 12 PIN CONNECTOR MOLEX MINI PCB 16 PIN ri E ERE CAPACITOR PEF 0 1 100V 10 8 Macc CAPACITOR PEF 0 22 100V 10 974 MONETE RE CAPACITOR PEF 047 200V 1096 ou CAPACITOR CD 02 600V 80 20 CS MP CAPACITOR CD 05 600V 80 20 C21 022 028 icin siiis ani CAPACITOR PEF 0 1 400V 10 DZB ser e ZENER DIODE 5W 15V 5 6 1N5352B 073 079 0710 ZENER DIODE 1W 15V 5 1N4744A DZ Ls ee ee eee ee ZENER DIODE 5W 17V 5 1N5354B 01 03 04 05 06 08 09 013 TRANSISTOR N T226 0 5A 40V 2N4401 Q14 Q16 92 015 setae lee aie ae ere TRANSISTOR P T226 0 5A 40V 2N4403 D55 D56 D61 D64 DIODE AXLDS 1A 400V FR 1N4936 8119 9120 celos REED RESISTOR CC 1W 3 3 5 inline RESISTOR CC 2W 15 5 aie tne ae nada RESISTOR CC 1 2W 100 5 R23 R24 scusa e m Rma RESISTOR CC 1 2W 150 5 H25 H26 H75 cesse RESISTOR CC 1 2W 330 5 GAJ aoa boa erage CAPACITOR PEMF 047 100V 10 TRANSISTOR ND T220 5A 100V TIP122 R27 R31 R33 R85 R102 R127 RESISTOR MF 1 4W 100 1 R128 R164 R12 R18 R19 R38 R48 R53 RESISTOR MF 1 4W 1 00K 1 R56 R60 R63 R65 R68 R72 R73 R74 R80 R121 R159 R169 R175 R176 62 CAPACITOR CEMO 4700P 50V 10 i cee enne CHOKE 330UH 10 110MA MOLDED COB ae ei ie CAPACITOR CD 0047 3000V
21. au 5 TER 818 EJE y DIH o iac Return to Section TOC Return to Master TOC MAINTENANCE D 2 CAPACITOR DISCHARGE PROCEDURE PROCEDURE NOTE See Figure D 1 1 Disconnect input power to the machine 2 Remove the Left Case Side Assembly 3 Locate the two capacitors shown Figure D 1 and D 2 4 Put on the insulated gloves 5 Grip the middle of the resistor with the insulated pliers Touch the resistor leads across the two capacitor straps as shown for 10 seconds a DO NOT TOUCH THE CAPACITOR STRAPS WITH YOUR HANDS OR ANY OTHER PART OF YOUR BODY Test for zero volts across the capacitor terminals with a DC voltmeter a Capacitor terminal polarity is marked on the capacitor straps b If any voltage is measured REPEAT PROCEDURE INSULATED PLIERS FIGURE D 1 Capacitor Discharge Procedure LINCOLN amp ELECTRIC PRO CUT 60 D 3 MAINTENANCE ROUTINE AND PERIODIC Perform Periodically MAINTENANCE Clean inside the machine with a low pressure air 1 Disconnect input power supply lines to the Stream the following components Refer to machine before performing periodic main tenance GA cleaning or replacing s Mantandomier parts SeelFigure D 2 e Torch pilot and work connections Spark gap Inspect for 060 spacing Control board e Power board Heatsink fins Fan motor and blade Return to Section TOC Return to Master T
22. courages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine Return to Section TOC Return to Master TOC LINCOLN 3 PRO CUT 60 G 14 ELECTRICAL DIAGRAMS BYPASS PC BOARD M17322 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC CO lt gt cn LLI N lt a LU co CO D O O oc au FE nile 818 EJE Bi WV iac NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is provided for reference only Lincoln Electric dis courages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine PRO CUT 60 LINCOLN Return to Section TOC Return to Master TOC Return to Section Return to Master TOC Return to Section TOC Return to Master TOC
23. 02 ASBLY C505 95 x Y 0508 zs 400V i H2 z L 389 PILOT O J ic TO PRIMARY C506 389 TO GROUND 460 575V 208 230 460V 1 BOARD 1775 0047 PER NATIONAL MAIN TRANSFORMER 1 POS sd T 3000V pud ELECTRICAL CODE 5W GENERAL INFORMATION 37 TO SUPPLY 575 LI LI ELECTRICAL SYMBOLS PER E1537 1 5 391 LINES 5 40 RESISTORS OHM WATT 1 2 WATT UNLESS 7 1 sow aii OTHERWISE SPECIFIED 2 CAPACITORS MFD VOLTS NOTES TRANSISTOR MODULE AUXILIARY COILS N A NUMBER 318 CONNECTED TO THE NOZZLE eR bese H3 H4 12 VAC PILOT LEAD AT THE TORCH i 320 power ROS 51 TO PRIMARY H6 C2 24 VAC 6 7 amp 8 APPEAR ON TRIPLE VOLTAGE i ELE TO GROUND COILS 31 32 115 VAC amp 208V SINGLE MACHINES ONLY MEE NATIONAL C1 32 24 VAC WORK ELECTRICAL CODE 10 8 93R CLEVELAND OHIO U S A NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels L7830 PRO CUT 60 ELECTRICAL DIAGRAMS CONTROL BOARD SCHEMATIC DRAWING G2015
24. 1 7322 G 14 Wiring Diagram Codes 10112 10118 G 16 8 Wiring Diagram Codes 9819 100960 G 17 8 Control Board Schematic 62015 G 18 Power Board Schematic 117941 G 19 Q 7 4 gt 4 c 5 Return to Master PRO CUT 60 G 2 ELECTRICAL DIAGRAMS STATUS BOARD SCHEMATIC DIAGRAM Return to Section TOC Return to Master TOC STATUS BOARD SCHEMATIC 18648 PROCUT 60 Return to Section TOC Return to Master TOC LO jam Lu am 1 O a gt 1 lt O Lu Lu FE au nile 818 EJE Bi o iac NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is provided for reference only Lincoln Electric dis courages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine PRO CUT 60 LINCOLN Return to Section TOC Return to Master TOC Return to Section
25. 7 0 To avoid scalding do not remove the radiator pressure cap when the engine is hot Return to Master TOC PRO CUT 60 Return to Master Return to Master TOC Q ks 7 41 gt 4 c 5 5 Return to Master SAFETY PRECAUTIONS DE SURETE Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 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 conne
26. LED lights for a short time but no pilot arc is established OUTPUT PROBLEMS The pilot arc will shut off after 2 5 seconds unless it is brought in contact with the work and the cutting arc is established This is a normal condition Check the torch consum ables to be sure they are installed properly Make sure they are not dirty or greasy and are in good con dition Replace the consum ables if necessary Check for the presence of high frequency spark at the spark gap located inside the right panel of the machine The spark will normally be present for a second or two when the torch trigger is pulled Check the high frequency spark gap setting It should be set at 060 1 5mm DISCONNECT ALL INPUT POWER BEFORE ADJUST ING THE HIGH FREQUEN CY CIRCUIT The machine s upper com partment could be dirty blow out the upper compartment with compressed air 1 the Control The torch and cable assem Perform Torch Torch Cable Assembly and Internal Trigger and Safety ircuit 16515 If the high frequency spark is present at the spark gap for 1 second go to step 3 If the high frequency spark is not present at the spark gap check that the pilot control relay CR2 contacts close when the torch trigger is pulled a f pilot control relay CR2 contacts close when torch_trig ger_is pulled perform b If pilot control relay CR2 contacts DO NOT close test for 115 VAC between leads
27. Remove the two nylon nuts from the studs on which the Power Board is mounted with a 7 16 nut driver Remove the Power Board by pulling it out clear of the studs and lifting it straight up out of the machine Install replacement Power Board by sliding it over the mounting studs Replace the nylon nuts loosely on the mounting studs so the Power Board position can be adjusted when installing the mounting and terminal screws Install the four mounting screws finger tight Connect leads H1 and H2 to the SCR modules with the terminal screws finger tight Connect leads C two wires NEG and 40 two wires with the terminal screws finger tight 16 17 18 19 Tighten the six screws connect ing the Power Board to the SCR modules to 35 in Ibs 3 9 N M Tighten the three screws connecting the C NEG and 40 leads to the Power Board and the Transistor Module to 17 in lbs 1 9 N M Tighten the nylon nuts on the mounting studs Reconnect tightly all Molex Plugs J20 J21 and J22 and plug in spade lug leads marked G1 G2 40 and B through the Power Board to terminals on the SCR modules F 40 PRO CUT 60 41 TROUBLESHOOTING amp REPAIR TRANSISTOR MODULE REMOVAL AWARNING Service and repair should be performed only by Lincoln Electric factory trained per sonnel Unauthorized repairs performed on this equipment could result in danger to the technician or the mach
28. TROUBLESHOOTING amp REPAIR HOW TO USE TROUBLESHOOTING GUIDE PRO CUT 60 Service and Repair should only be performed by 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 pos sible symptoms that the machine may exhib it Find the listing that best describes the symptom that the machine is exhibiting Symptoms are grouped into several main categories output problems function prob lems airflow problems and cutting prob lems Step 2 PERFORM EXTERNAL TESTS The second column labeled POSSIBLE AREAS OF MISADJUSTMENT S lists the obvious external possibilities that may con tribute to the machine symptom Perform these tests checks in the order listed In general these tests can be conducted with out removing the case wrap around cover Step 3 PERFORM COMPONENT TESTS The last column labeled Recommended Course of Action lists the most likely com ponents that may have failed in your machi
29. to make contact with the lead See Figures _F 1 E2 and for component and lead connec tion locations Refer to wiring diagram Lead 2 on Lead H6 on 3 Control Board at Control Board at 24 VAC Plug location 1J7 Plug location 3J7 4 Lead H3 on Lead 4 on Power Board at Power Board at 12 VAC Plug location 3J22 Plug location 1J22 Table F 2 Auxiliary Winding Tests LINCOLN amp ELECTRIC Return to Section Return to Master TOC Return to Section TOC Return to Master TOC nile 818 EJE Bi o iac Return to Section TOC Return to Master TOC TROUBLESHOOTING amp REPAIR F 26 MAIN TRANSFORMER TEST PC BOARD RELAY POWER PC FIGURE F 10 Main Transformer Test Components S zI Li TO TOUCH METER PROBE TO LEAD 31 CONNECTED TO THE COIL OF THE CONTACTOR LEAD 31 FIGURE F 10A CR2 Lead Locations for Table F 2 PRO CUT 60 27 TROUBLESHOOTING amp REPAIR POWER BOARD TEST A WARNING Service and repair should be performed only by Lincoln Electric factory trained per sonnel Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and pre cautions detailed throughout this manual Return to Section TOC Return to Master TOC If for any reason you
30. 20 oop ose nes die Rs ZENER DIODE 1W 12V 5 1N4742A RIS ote a hea ates RESISTOR MF 1 4W 243 1 Dn RESISTOR MF 1 4W 8 25K 1 ip CRYSTAL QUARTZ 3 579545MHZ e TA OPTOCOUPLER TRIAC DRIVER 3023 CAPACITOR PEF 0 22 400V 10 Drm DIODE AXLDS 3A 600V 1N5406 FAQ 3184 dr ERE bkn RESISTOR WW 5W 390 596 R78 R181 R182 RESISTOR MF 1 4W 90 0K 196 SCRA ave SCR T220 25A 600V 2N6508 or err DD CAPACITOR CEMO 0 1 50V 1096 eos ORIS doe IC VOLT REG FIXED 3 T 1A 5V XQ xcu RS RUE IC VOLT REG FIXED 3 T 1A 15V NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is provided for reference only Lincoln Electric dis courages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine LINCOLN amp PRO CUT 60 G 8 ELECTRICAL DIAGRAMS POWER BOARD NANNING ANININ AN ININININ 2 Return to Section Return to Master TOC
31. 3 Check work cables and the transistor module is but the cutting arc does not connections faulty replace the Power transfer to the work Clean any painted or heavily Board also corroded work surfaces If no malfunction or fault indi cators are lit then contact your local Lincoln Authorized Field Service Facility FE a 5 US TER 818 EJE Bi iac CAUTION If for any reason you do not understand the test procedures are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216 383 2531 or 1 800 833 9353 PRO CUT 60 Return to Section TOC Return to Master TOC TROUBLESHOOTING amp REPAIR F 8 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION OUTPUT PROBLEMS The OUTPUT ON and MAL The pilot arc duty cycle has Make sure operator is not FUNCTION or FAULT LED s been exceeded The exceeding pilot arc duty cycle blink in alternating order No machine should cool down pilot arc and the lights quit blinking in 20 seconds The pilot arc duty cycle is limited to 20 out of 80 seconds except in spe cial circumstances such as cutting expanded metal Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC
32. 36 and 31 on pilot control relay CR2 when the torch trig ger is pulled Refer to wiring diagram If 115 VAC is present pilot control relay CR2 could be faulty Replace 115 VAC IS NOT present check plug J10 on Control Board and associated wires for loose or faulty connections Refer to wiring diagram If none are found Control Board could be faulty Replace Check resistor R2 Normal resistance is 2 ohms Refer to wiring diagram Check resistor R7 resistance is 5 ohms wiring diagram Check the two jump start diodes mounted on a plastic board just in front of the shunt Refer to wiring diagram If check 3 4 and 5 are OK Board could be faulty Replace Normal Refer to CAUTION If for reason you do understand the test procedures are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216 383 2531 or 1 800 833 9353 LINCOLN 8 ELECTRIC Return to Section TOC Return to Master TOC PRO CUT 60 7 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION OUTPUT PROBLEMS The THERMAL LED is lit The machine may be over The normally closed The MALFUNCTION or heated This condition may primary thermostat could FAUL
33. 8 d 1 Route the electrode and work cables together Secure start engine until fumes have been them with tape when possible eliminated 8 d 2 Never coil the electrode lead around your body 8 d 3 Do not place your body between the electrode and work cables If the electrode cable is on your right Keep all equipment safety guards covers side the work cable should also be on your right side and devices in position and in good repair Keep hands hair clothing and tools away d 4 Connect the work cable to the workpiece as close as from V belts gears fans and all other possible to the area being welded moving parts when starting operating or Return to Master TOC repairing equipment d 5 Do not work next to welding or cutting power source 7 e some cases it may be necessary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts Do not put your hands near the engine fan Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running Q O ks 7 4 gt 4 c 5 5 To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate
34. C26 C43 C44 CAPACITOR TAEL 4 7 35V 10 R86 R87 R145 R179 R180 RESISTOR MF 1 4W 33 2K 196 642 CAPACITOR TAEL 2 7 50V 10 R28 R29 R34 R84 R99 R108 RESISTOR MF 1 4W 475 1 C6 C50 C53 C54 C55 C58 C60 CAPACITOR PCF 0 027 50V 20 C64 C65 C66 C67 R153 R154 R155 RIO s a mede Si anara ata ee RESISTOR MF 1 4W 4 75K 1 R22 R58 R138 R146 R147 RESISTOR MF 1 4W 5 11K 1 RESISTOR MF 1 4W 5 62K 1 FAQ xp soar aided RESISTOR MF 1 4W 681 1 R5 R6 R10 R61 R141 RESISTOR MF 1 4W 6 81K 1 iei RESISTOR MF 1 4W 68 1K 1 RIGG FT RESISTOR MF 1 4W 68 1 1 XO X IC OP AMP QUAD GEN PURPOSE 224N OCI6 OCI7 OCI9 OPTOCOUPLER PHOTO Q 70V CNY17 3 DZI ZENER DIODE 1W 10V 5 1N4740A DZO ZENER DIODE 1W 6 2V 5 1N4735A DZ2 DZ4 DZ5 DZ13 DZ14 DZ15 ZENER DIODE 1W 5 1V 5 1N4733A DZ17 DZ18 DZ19 DZ20 DZ21 QUE Mats TRANSISTOR NMF 4PDIP 1A 100V RFD110 C9 C15 C17 018 C19 C28 C51 CAPACITOR TAEL 1 0 50V 10 eect ale RS CAPACITOR ALEL 3300 50V 30 10 10 16 639 40 41 CAPACITOR PEMF 0 33 200 10 1 2 OPTOCOUPLER TRIAC DRIVER ZVC 3043 1 2 TRIAC T220 6A 400V JI
35. Return to Section TOC Return to Master TOC oio nile 818 EJE Bi WV iac NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is provided for reference only Lincoln Electric dis courages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine Return to Section TOC Return to Master TOC PRO CUT 60 LINCOLN ELECTRICAL DIAGRAMS G 13 BYPASS PC BOARD M15603 Qo 25 518 Blu 2 Hei 554555556626 Identification 9 E E 1 6668010 csocsi 0 047uF 1000V 10 ajz 4 C2 C4 C7 C9 0 05uF 600V 80 20 0 0047UF 1400V 1 2 320V 160 MOV Return to Section TOC Return to Master TOC FE au nile 818 EJE 5 5 Bi o iac NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is provided for reference only Lincoln Electric dis
36. Section TOC Return to Master TOC FE au nile 818 EJE Bi o iac Return to Section TOC Return to Master TOC LINCOLN amp ELECTRIC TROUBLESHOOTING amp REPAIR F 24 MAIN TRANSFORMER TEST A WARNING Service and repair should be performed only by Lincoln Electric factory trained per sonnel Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and pre cautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 216 383 2531 or 800 833 9353 WELD TEST DESCRIPTION This test will identify any problems or faults in the Main Transformer s primary and secondary windings These tests require that the machine be connected to the input power supply and turned ON MATERIALS NEEDED Volt Ohmmeter Multimeter PRO CUT 60 Wiring Diagrams PRO CUT 60 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC FE a 5 gt 818 EJE Bi iac Return to Section TOC Return to Master TOC F 25 TROUBLESHOOTING amp REPAIR MAIN TRANSFORM
37. TOC This test will identify any problems or faults in the torch torch cable assembly and associated circuits MATERIALS NEEDED Volt Ohmmeter Multimeter PRO CUT 60 Wiring Diagrams PRO CUT 60 Torch Spare Parts Kit Supplied 9 16 Open end wrench FE au nile 818 EJE Bi o iac Return to Section TOC Return to Master TOC PRO CUT 60 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC FE au nile 818 EJE Bi o iac Return to Section TOC Return to Master TOC 1 2 e 4 TROUBLESHOOTING amp REPAIR F 16 TORCH TORCH CABLE ASSEMBLY INTERNAL TRIGGER AND SAFETY CIRCUIT TEST TORCH AND CABLE RESISTANCE TEST PROCEDURE Turn PRO CUT 60 ON OFF Power Switch to OFF Disconnect main power supply to machine Perform the CAPACITOR DISCHARGE PROCEDURE Disconnect and remove the torch cable from the bulkhead com partment See Figure F 3 a Locate the torch cable access door on the Right Case Side Assembly of the machine b Remove the one sheet metal screw on the left hand side of the access door and swing open the door Test for a voltage across the stud marked WORK and the bulkhead connector brass fitting NO voltage should be present If a voltage is present STOP DO NOT perform this test Contact the Lincoln Electric Service Department If no voltage is present contin
38. a cylinder the cylinder must have a pressure regulator e Maximum psi from nitrogen gas cylinder to PRO CUT 60 regulator should never exceed 120 psi 827 kPa Install a hose between the nitrogen gas cylinder regulator and the PRO CUT 60 regulator s gas inlet PRO CUT 60 A WARNING CYLINDER could explode if damaged Keep cylinder upright and chained to a fixed support Keep cylinder away from areas where it could be damaged Never lift machine with cylinder attached Never allow the cutting torch to touch the cylinder Keep cylinder away from live electrical parts Maximum inlet pressure 120 psi 827kPa LINCOLN E ELECTRIC Return to Section Return to Master TOC Return to Section TOC Return to Master TOC nile 818 EJE Bi o iac Return to Section TOC Return to Master TOC INSTALLATION RECONNECT PROCEDURE Multiple voltage machines are shipped connected to the highest input voltage listed on the machine s rating plate Before installing the machine check that the Reconnect Panel in the Input Box Assembly is connected for the proper voltage CAUTION Failure to follow these instructions can cause immediate failure of components within the machine To reconnect the machine to a different voltage change the position of the power straps links on the reconnect panel assembly Follow The Input Supply Connection Diagram located on
39. a safety mechanism that assures consumables are in place before cutting or gouging This is extremely important due to the high voltages involved Two standard torch cable lengths are available a 25 ft 7 6m torch cable or a 50 ft 15 2m torch cable The machine also comes with an air regulator coarse air filter pressure gage and spare parts kit The standard undercarriage is shipped assembled except for the handle RECOMMENDED PROCESSES AND EQUIPMENT The PRO CUT 60 is capable of all cutting and gouging applications within its output capacity of 25 to 60 amps These applications include thin gage sheet metal and expanded metal OPERATIONAL FEATURES AND CONTROLS The PRO CUT 60 comes with an ON OFF POWER SWITCH OUTPUT CURRENT CON TROL and a RUN PURGE SWITCH DESIGN FEATURES AND ADVANTAGES The microprocessor controlled PRO CUT 60 design makes plasma cutting and gouging tasks uncomplicated This list of design features and advantages will help you understand the machine s total capabilities so that you can get maximum use of your machine LINCOLN amp ELECTRIC B 2 Single continuous output range of 25 60 amps Microprocessor controlled overshooting limiting function increases consumable life High intensity high frequency starter Unique microprocessor controlled starting sequence for consistent starting and torch protection Solid state pilot duty cycle limiting Protects components without fuses th
40. area Remove the three Phillips head screws holding the torch handle together Unplug the red and white safety leads in the torch head 7 Remove the tape insulation carefully Save the tape and insulation to re apply during assembly The insulation is extremely important because of the high voltages present in the torch head during operation Loosen and remove the brass compression nut closest to the torch head Use fi 13mm wrench to loosen the brass compression nut Support the brass nipple while turning the nut Install replacement torch head in reverse order of removal a Tighten the brass compres sion nut to 75 in lIbs b Re apply the insulation and tape the outer seams of the insulation c Reconnect the red and white safety circuit leads d Insert the trigger and cable assembly into the torch handle making sure that the hole on each side of the cable strain relief lines up with the tabs in the torch handle sides e Replace the three Phillips screws TROUBLESHOOTING amp REPAIR F 52 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 repaired or replaced the machine must be retested Return to Section TOC Return to Master TOC INPUT IDLE AMPS INPUT VOLTS HERTZ MAXIMUM IDLE AMPS 208 60 460 60 2
41. lbs Partially tighten each cap screw one at a time to avoid uneven torque on the base plate Install replacement Power Board See ROWER BOARD REMOVAL PROCEDURE F 42 PRO CUT 60 43 TROUBLESHOOTING amp REPAIR SCR MODULE REMOVAL A WARNING Service and repair should be performed only by Lincoln Electric factory trained per sonnel Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and pre cautions detailed throughout this manual Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 216 383 2531 or 800 833 9353 WELD CAUTION Printed Circuit Boards can be damaged by static electricity Return to Section TOC Return to Master TOC REMOVAL REPLACEMENT DESCRIPTION This procedure will assist you in removing or replacing the SCR Modules MATERIALS NEEDED 4mm Allen type wrench Static grounding strap Replacement SCR Module Joint Compound Lincoln T12837 or equivalent Dow Corning 340 FE au nile 818 EJE Bi o iac Return to Section TOC Return to Master TOC PRO CUT 60 R
42. nor mal operating temperature LIMITATIONS Do not exceed output current and duty cycle rat ing of machine Do not use the PRO CUT 60 for pipe thawing CONTROLS AND SETTINGS All operator controls and adjustments are located on the Case Front Assembly of the PRO CUT 60 See Figure B 1 for the location of each control 1 SAFETY RESET BUTTON The SAFETY RESET BUTTON is pressed to resume opera tion after the SAFETY LED glows and the operating problem is cleared 2 PURGE RUN SWITCH This switch controls the air supply to the machine In the PURGE position air flows continuously through the torch to allow for the adjustment of air pres sure Note that the output is disabled in this mode In the RUN position air flows through the torch when the torch trigger is activated PRO CUT 60 OPERATION 3 STATUS LED DISPLAY The machine conditions are displayed following MACHINE ON LED The green POWER ON LED glows when the POWER LINE SWITCH is in the ON position and AC power is con nected to the machine OUTPUT ON LED The OUTPUT ON LED glows when the pilot arc starts and remains glowing during cutting AIR PRESSURE LED The AIR PRESSURE LED glows whenever there is adequate air pressure above 50 psi THERMAL LED The THERMAL LED glows when the machine overheats FAULT LED MALFUNCTION LED The FAULT LED glows blinks if a short circuit has occurred in the torch in the machine or when the air pressure is too l
43. 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 contre les chutes dans le cas ou on recoit un choc Ne jamais PRECAUTIO NS DE 0 enrouler le c ble lectrode autour de n importe quelle partie du corps LES MACHINES A SOUDER A TRANSFORMATEUR ET A donc REDRESSEUR Un coup d arc peut tre plus s v re qu un coup de soliel a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du ray onnement de et des projections quand on soude ou quand on Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc 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 lat
44. sizes work better and provide longer life but produce wider kerfs cuts Use a current level setting that is adequate to produce an acceptable cut at maximum travel speed Operating at a current level that exceeds the requirements needed to cut the metal results in poor cutting quality and machine operation Cut thin gage sections of aluminum copper and other non ferrous metals using a higher current range If acceptable results are not obtained use the procedures listed under Cutting Thick Sections of Metal 3 99 PRO CUT 60 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 5 2 2 Return to Section o HF D 7 S 5 Return to Master TOC B 7 Cutting Expanded Metal hk Cut expanded metal with OUTPUT CURRENT CONTROL set near the mid range position using the same methods listed under Cutting Thin Gauge Metal Keep the following points in mind a Place a thin piece of scrap metal over the area to be cut and then cut through both to make cutting easier b After 30 seconds of cutting expanded metal the pilot arc changes from a bright continuous arc to an arc that rapidly goes on off This produces a slight spatter You can still cut metal when this condition occurs as long as metal has been cut in the last five seconds If metal is not cut in this condit
45. the SCR Module mounting surface Use Lincoln Joint Compound T12837 or equivalent such as Dow Corning 340 Press the SCR Module onto the heat sink surface Remove the module to make sure enough joint compound has been applied When removed both surfaces should have an even texture with no bare spots f this even textured look does not appear re apply the joint compound e Mount the SCR Module on the heat sink with the 4mm Socket head cap screws to 35 in Ibs 3 9 N M Partially tighten each cap screw one at a time to avoid uneven torque on the base plate Install Power Board See POWER BOARD REMOVAL REPLACEMENT PROCEDURE LINCOLN 8 ELECTRIC TROUBLESHOOTING amp REPAIR F 46 FAN BLADE AND FAN MOTOR REMOVAL REPLACEMENT A WARNING Service and repair should be performed only by Lincoln Electric factory trained per sonnel Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and pre cautions detailed throughout this manual Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 216 383 2531 or 800 833 9353
46. the arc to the work piece for cutting Do not start the pilot arc repeatedly over short periods of time This could reduce consum able life Start the pilot arc and then make and fin ish the cut before releasing the trigger If the pilot arc sputters or does not start each time the torch trigger is pulled check the consumable for wear or high air pressure If either is found take proper action Cutting and Gouging Recommendations General 1 Make a continuous cut Do not pause during cutting gouging or at the end of the work piece Stopping and starting causes poor cuts and results in poor machine operation In addition it reduces consumable life 2 Position the torch so that dross and hot air cannot be deflected into the torch 3 Do not drag the nozzle when cutting above the mid range setting Above mid range always hold the torch 1 8 away from the work piece 4 Proper drag cup shield cup use gives you maximum nozzle and consumable life When operating in the blue or red current ranges use a drag cup when possible When operating in the yellow range use a drag cup or a shield cup 5 Use the proper machine setting for the work to be done Adjusting the machine to maximum output does not produce the best cutting in most situations LINCOLN 8 ELECTRIC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o LE 2 o 2 5
47. the inside of the access door 1 For 208 230 460 VAC machines see Figure A 3a 2 For 460 575 VAC machines see Figure A 3b LINCOLN 8 ELECTRIC 460 V 60HZ GND 777 L1 L2 USE FERRULE 10 AWG ONLY O o ojo A 6 LINK POSITIONS LINK o 6 9 o o LINK POSITIONS LINK e 5 5 o o LINK POSITIONS LINK D B3 e FIGURE A 3a Voltage Link Positions for 208 230 460 VAC machines USE FERRULE 10 AWG ONLY 460 V 60HZ L1 L2 o LINK POSITIONS o o LINK FIGURE A 3b Voltage Link Positions for 460 575 VAC machines PRO CUT 60 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC c T o 72 dei I Return to Section TOC Q O H f 0 41 gt 4 c 5 Return to Master A 7 OUTPUT CONNECTIONS A WARNING To avoid receiving a high frequency shock keep the torch and cables in good condition The standard PRO CUT 60 cutting torch comes with a 25 ft 7 6m cable A cutting torch with a 50 ft 15 2m cable is available The PRO CUT 60 is shipped with the torch and work cables already connected Should you have to connect the torch or work cables use the followi
48. the job and have taken all safety precautions It is important to follow these operating steps each time you use the machine 1 Turn the machine s ON OFF POWER SWITCH to OFF position 2 Connect air supply to the machine 3 Turn on main AC power supply to the machine 4 Turn the machine s ON OFF POWER SWITCH to ON The green POWER ON LED glows The fan starts LINCOLN 8 ELECTRIC NOTE If the SAFETY LED glows press the SAFETY RESET button If there is no prob lem the SAFETY LED will go off If the SAFE TY LED remains on turn the ON OFF POWER SWITCH to OFF and refer to the TROUBLESHOOTING GUIDE in the TROU BLESHOOTING AND REPAIR SECTION of this manual for a recommended course of action Set the PURGE RUN switch in the PURGE position The air flow starts The AIR PRESSURE LED glows Adjust air pressure to 60 psi with the air flowing Move the PURGE RUN SWITCH to RUN Postflow air flows for 20 seconds During this time the pilot arc immediately starts when the torch trigger is pulled After 20 seconds air preflows for two seconds PRO CUT 60 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC 9 E 9 4 k 42 ac Return to Section TOC Q O H f 0 41 gt 4 c 5 5 a Return to Master TOC B 5 8 Pull the torch trigger to cut OUTPUT ON LED glows If postflow h
49. 0 575 60 1 6 Return to Section TOC Return to Master TOC MAXIMUM ACCEPTABLE OUTPUT VOLTAGE AT MINIMUM OUTPUT SETTING Output Control at Minimum 26 Amps 43VDC MINIMUM ACCEPTABLE OUTPUT VOLTAGE AT MAXIMUM OUTPUT SETTINGS Output Control at Maximum 60 Amps 90VDC RECOMMENDED METERS FOR MACHINE OUTPUT TESTS nile 818 EJE Bi o iac VOLTMETER Analog type meter Return to Section TOC Return to Master TOC PRO CUT 60 LINCOLN NOTES F 53 PRO CUT 60 DOL ISe W DOL J893se A DOL 4 1 DOL JSE W DOL gt 5 oj DOL uonoes 03 uum DOL uonoes 03 DOL uonoes oj TABLE OF CONTENTS Section G ELECTRICAL DIAGRAMS F 9 9 Electrical Diagrams ern peat SRI e esas Roma PA DA RU Section G Status Board Schematic M18601 2 5 sce bldi eec de G 2 9 Bypass Board Schematic 15603 2 HR ERI URBES G 3 Bypass Board Schematic M17322 ssec eese ttis iretur eie G 4 Control Board Components G 6 Power Board 17941 02 2222 0 0 00 00 6 8 Status Board Components 15601 G 10 Y Bypass Board Components 15603 G 12 Bypass Board Components
50. 130 R150 C36 C45 100 100 5 R151 R152 R165 R170 R171 C5 C8 C12 C13 C27 C30 C31 CAPACITOR CEMO 022 50V 20 R172 R173 C38 C52 C56 R140 RI42 R143 RESISTOR MF 1 4W 100K 1 canoes cece CONNECTOR MOLEX MINI PCB 4 PIN 144 RESISTOR MF 1 4W 1 00M J2 10 CONNECTOR MOLEX MINI PCB 6 PIN R76 RESISTOR MF 1 4W 10 0 1 J5 CONNECTOR MOLEX MINI PCB 8 PIN 46 90 93 RESISTOR MF 1 4W 1 50K 1 CAPACITOR 150uF 50V 150 10 R55 R62 R66 RESISTOR MF 1 4W 200 1 D1 D2 D3 D4 D5 D6 D7 D8 D9 DIODE AXLDS 1A 400V R30 R45 R57 R59 R69 R83 RESISTOR MF 1 4W 2 21K 196 D10 D11 D12 D13 D14 D24 R157 R158 R174 D25 D35 D36 D46 D47 D48 101 8137_ RESISTOR MF 1 4W 22 1K 1 D49 D50 D58 D59 D69 D70 R70 R89 R91 R100 R139 R156 RESISTOR MF 1 4W 221K 1 071 e denne E RESISTOR MF 1 4W 267 1 D26 D27 D29 D30 DIODE AXLDS 1A 1000V 1 54 64 67 RESISTOR MF 1 4W 26 7 1 CHOKE 5 6MH 10 28MA MOLDED 71 148 149 RESISTOR MF 1 4W 3 01K 1 L1 L2 L3 L4 CHOKE 5 0MH 5 160MA CONFORMAL SLV Ee EE RESISTOR MF 1 4W 332 1 pies TRANSFORMER PULSE 3 WINDING 1 1 1 R47 R129 R168 R177 R178 RESISTOR MF 1 4W 3 32K 196 C2 C4
51. 2 Test Procedures Capacitor Discharge 13 14 Torch Torch Cable Assembly Internal Trigger amp Safety Circuit Test F 15 F 20 Transistor Module intro rep pese Revenues atender dos F 21 F 23 Main Transformer F 24 F 26 5 Power Board ei F 27 F 30 High Voltage Transformer and Circuit F 31 F 33 p Replacement Procedures 8 On Off Power Switch Removal sse F 34 F 35 c Control Board Berroval F 36 F 37 Power Board 38 F 40 Transistor Module F 41 F 42 SCR Module nnns F 43 F 45 Fan Blade and Fan Motor F 46 F 48 Torch Head F 49 F 51 Reest Aler iiie ee F 52 Q 0 4 gt 4 c 5 Return to Master PRO CUT 60 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC c T o dei I Return to Section TOC Return to Master TOC Q O H f 0 41 gt 5 F 1
52. 3 9353 LINCOLN 8 ELECTRIC PRO CUT 60 5 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE dm Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC lu nile 818 EJE Bi WV aic The air begins to flow the OUTPUT ON LED lights for a short time but no pilot arc is established The high frequen cy arc does NOT appear across the torch tip OUTPUT PROBLEMS Check the torch consum ables to be sure they are installed securely Make sure they are not dirty or greasy and are in good con dition Replace the consum ables if necessary Check for the presence of high frequency at the spark gap located inside the Right Case Side Assembly panel of the machine The spark normally will be present for a second or two when the torch trigger is pulled Check the high frequency spark gap setting It should be at 060 1 5mm DIS CONNECT ALL INPUT POWER BEFORE ADJUST ING THE HIGH FREQUEN CY CIRCUIT If the high frequency spark is present at the spark gap located inside the panel the torch and cable assembly may be faulty 1 1 the high 2 lf the high frequency spark is present at the spark gap located inside the panel the torch and cable assembly may be f
53. C PRO CUT 60 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC FE a 5 TER 818 EJE 21 iac TROUBLESHOOTING amp REPAIR TRANSISTOR MODULE TEST MATERIALS NEEDED Analog Volt Ohmmeter Multimeter with RX10 or RX1000 scale PRO CUT 60 Wiring Diagrams Phillips Head Screwdriver TEST PROCEDURE 1 Turn ON OFF Power Switch to OFF 2 Disconnect main input power to machine 3 Perform the CAPACITOR DISCHARGE PROCEDURE 4 Locate Power Board See Figure F 8 5 Locate and remove the leads marked 40 by removing the terminal screw connecting them to the Power Board See a Move the leads out of the way 6 Replace the terminal screw snugly a little more than finger tight The Transistor Module is mounted behind the Power Board and the terminal screw completes the electrical connection Locate and remove the one lead marked NEG by removing the terminal screw connecting it to the Power Board See Figure 9 a Move the lead out of the Replace the terminal screw snugly a little more than finger tight The Transistor Module is mounted behind the Power Board and the terminal screw completes the electrical connection Remove the two leads marked C by removing the terminal screw connecting them to the Power Board See Figure 9 a Move the lead out of the way NEGATIVE PROBE POS
54. C 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 CAUTION Sometimes machine failures appear to be due to PC board failures These problems can sometimes be traced to poor electrical connections To avoid problems when troubleshooting and replacing PC boards please use the following procedure 1 Determine to the best of your technical abili ty that the PC board is the most likely com ponent causing the failure symptom 2 Check for loose connections at the PC board to assure that the PC board is properly con nected 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 P C Board can be dam aged by static electricity Remove your body s stat ic charge before opening the static shielding bag Wear an anti static wrist strap For safety use a 1 Meg ohm resistive cord connected to a grounded part of the equipment frame ATTENTION Static Sensitive Devices Handle only at Static Safe Workstations Reusable Container Do Not Destroy f you don t have a wrist strap touch an unpainted grounded part of the equipment frame Keep touching the frame to prevent static build up Be sure not to touch an
55. Company Your Name Please give detailed description below SD287 01 99 LINCOLN
56. DY 3 Locate the two capacitors shown 7 Test for zero volts across the in Figure F 19 capacitor terminals with a DC volt meter 4 Puton the insulated gloves a Capacitor terminal polarity is 5 Grip the middle of the resistor marked on the capacitor with the insulated pliers straps b If any voltage is measured REPEAT PROCEDURE Return to Section TOC Return to Master TOC INSULATED PLIERS FE au nile 818 EJE Bi o iac Return to Section TOC Return to Master TOC FIGURE F 19 Capacitor Discharge Procedure PRO CUT 60 15 TROUBLESHOOTING amp REPAIR TORCH TORCH CABLE ASSEMBLY INTERNAL TRIGGER AND SAFETY CIRCUIT TEST A WARNING Service and repair should be performed only by Lincoln Electric factory trained per sonnel Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and pre cautions detailed throughout this manual Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 216 383 2531 or 800 833 9353 WELD TEST DESCRIPTION Return to Section TOC Return to Master
57. E 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 copy of Safety in Welding amp Cutting ANSI Standard 249 1 from the American Welding Society Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PER FORMED ONLY BY QUALIFIED INDIVIDUALS ELECTRIC SHOCK can kill 1 a The electrode and work or ground circuits are electrically hot when the welder or cutter is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands 1 b Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding or cutting must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavo
58. ER TEST TEST PROCEDURE 1 Connect main input power supply to machine NOTE When performing Tests A and B a If any one voltage is missing or below the specification inspect the associated plugs and wiring If there are no loose plugs or wiring then the associated winding in the main transformer could be defective Replace the main transformer If all secondary and auxiliary voltages are missing then inspect the Reconnect Panel to make sure the machine is con nected for the proper operating voltage If the machine is con nected properly the primary winding in the main transformer could be defective Replace Test A Main Secondary Voltage Test Auxiliary Winding Test poet 21508 To Expected Voltage Lead 31 on Lead 32 on Control Control Board at 115 VAC Relay CR2 Plug location 6J10 Lead C1 on Lead 32 on 2 Control Board at Control Board at 24 Plug location 545 Plug location 6J10 PRO CUT 60 12 95 1 Locate on the Power Board leads H1 and H2 to the SCR module See 2 Turn ON OFF Power Switch to ON 3 Test for 190 VAC across leads H1 and H2 4 Tum ON OFF Power Switch to OFF Test B Auxiliary Winding Tests 1 Perform the four Auxiliary Winding Tests in Table F 2 Turn the ON OFF Power Switch to ON for each test Turn the ON OFF Power Switch to OFF between each test When testing a lead connected to a Molex plug carefully insert the probe into the cavity of the plug
59. F 34 ON OFF POWER SWITCH REMOVAL A WARNING Service and repair should be performed only by Lincoln Electric factory trained per sonnel Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and pre cautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 216 383 2531 or 800 833 9353 WELD REMOVAL REPLACEMENT DESCRIPTION This procedure will assist you in removing or replacing the ON OFF Power Switch MATERIALS NEEDED Slot head screw driver Replacement ON OFF Power Line Switch PRO CUT 60 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC lux 5 TER 818 EJE Bi 0 Return to Section Return to Master TOC F 35 TROUBLESHOOTING amp REPAIR ON OFF POWER SWITCH REMOVAL LATER CODES MAY HAVE TOGGLE SWITCH ON OFF POWER SWITCH KNOB SCREW SECURING KNOB FACE PLATE SCREWS SECURING FACE PLATE SWITCH L1 amp L2 LEADS T1 amp T2 LEADS FIGURE F 13 ON OFF Power Switch Removal Replacement REMO
60. Figures and for Torch and Cable Resistance Tests Points and Circuit Diagram a Test for resistance on 4 pin connector of 1 ohm or less continuity from pins 1 to 3 pin 3 to the pilot lead pilot lead to the torch nozzle pins 2 to 4 when the torch trigger is pulled NOTE Remove the torch nozzle with the supplied wrench to per form this test electrode lead to the torch electrode b Test for high resistance 500K ohm minimum from the pilot lead to the electrode lead SHIELD CUP ASSEMBLY TRIGGER ELECTRODE ASSEMBLY 4 PIN CONNECTOR END VIEW 4 PIN CONNECTOR ELECTRODE LEAD Return to Master TOC Return to Section TOC FIGURE F 4 Torch and Cable Resistance Test Points PRO CUT 60 LINCOLN amp ELECTRIC Return to Section Return to Master TOC Return to Section TOC Return to Master TOC nile 818 EJE Bi iac Return to Section TOC Return to Master TOC LINCOLN amp ELECTRIC TROUBLESHOOTING amp REPAIR F 18 TORCH TORCH CABLE ASSEMBLY INTERNAL TRIGGER AND SAFETY CIRCUIT TEST C If any of the above tests do not agree with the expected normal resistance specifications then the torch and or cable must be repaired or replaced CONDUCTOR IN GAS TUBE ELECTRODE d Go to INTERNAL TRIGGER AND SAFETY CIRCUIT TESTIif all resistance valu
61. GLE PHASE 60 HERTZ ONLY Standard Voltage Input Current at Codes Rated Output 208 230 460 50 45 23 10112 9819 460 575 23 18 10118 10096 RATED OUTPUT Duty Cycle Volts at Rated Amps 60 Duty Cycle 115 100 Duty Cycle 115 OUTPUT Current Open Circuit Pilot Current Range Voltage 25 60 MIN MAX 22 5 20 seconds z mps MIN MAX P 235VAC 280 VAC out of 80 seconds RECOMMEND INPUT WIRE AND FUSE SIZES For all plasma cutting applications Based on U S National Electrical Code Ambient Temperature 300C or Less AC Input Fuse Type 75 C Voltage at Super Lag Copper Wire in Conduit AWG IEC Sizes 60 Hertz Circuit Breaker Delay Type 208 230 50 AMPS 8 8 4mm 10 5 3mm 460 575 25 AMPS 10 5 10 5 3mm PHYSICAL DIMENSIONS INCLUDES LIFT BAIL AND UNDERCARRIAGE W O HANDLE Weight including Mechie Torch Cable Length 2oft 6m Oft 15 2m 322 Ibs 329 Ibs 146 kg 149 kg PRO CUT 60 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC FE 5 TER gis EJE E Bi iac Return to Section TOC Return to Master TOC INSTALLATION Read entire Installation Section before installing the PRO CUT 60 SAFETY PRECAUTIONS A WARNING ELECTRIC SHOCK CAN KILL e Only qualified personnel K should install this machine Turn the input power OFF at the disconnect switch or fuse box before working on the equi
62. GROUND TO PRIMARY TO GROUND COILS PER NATIONAL ELECTRICAL CODE 75 76 77 A TTT T T TT 5 gt 319 2 Y 2 38 aene 324 Au 5 amp AIR a 3 1 335 SOLENOID 31 321 Ke 14 18 J10 PURGE RUN T oL s D 5 SWITCH Kie CONTROL BOARD CONTROL BOARD 13 65 32 TO GROUND pu i M PER NATIONAL 5 PRIMARY J3 ELECTRICAL CODE 1 THERMOSTAT Kae 9 gt 90 727 mnm J4 CR2 32 1 PRESSURE 2 31 12 1 3 1 gt 4 SWITCH 11 1l iL HAUT 0000 2 7810163951121 mpm VOLTAGE a TRANSFORMER J7 s 8 6 ji 4 2 338 385 Aid 12110021 H6 3321 386 383 221 20 22 1 1 5 1 6 1 8 ni 80 Pa 6 10 7 12 9 16 J3 J6 J8 i CONNECTOR CAVITY NUMBERING SEQUENCE O 32 NALS 2 4 VIEWED FROM COMPONENT SIDE OF BOARD 332 AMPHENOL 1 1 Hf oN TON I 460 575V MAIN TRANSFORMER 6 CENTER 7 H4 i TO SUPPLY PRI ir lan I TO SU 4 3012 1 HH 223156 1 o 504 a H X TORCH LI BOTTOM 0 NEG BULKHEAD PRI 71 dL m HI FREQ i CONNECTOR 77
63. IMN3HlO SSIINN Mb T SWUO 500151539 SIN3NOdWOO 12VX3 3HL MOHS LON AVN WY X YIO SIHL D x 03141934S ISIMYIHLO 5531 1 A0S ZZO I SHOllOVdVO QNVOB 313148402 v 30 ALITIGV3ONVHOUBLNI JHL cero m cc NOLL23NNOO 3Wvu4 13 39 110 Add MS 1513 u3d STOGWAS 121412313 9 112344 LNOHLIM 39NVHO AVW QHVOS 111981 cca a V Is V AHLIDOHIO HO SIN3NOdAOO JINIS gt 5 lt 138 1 NOLLVINHO3NI 1V33N39 EESTI o Ea lt 4 6 5 30 NOISSIWH3d SS3NdX3 3HL LNOHLIM 0351 NO 035010510 38 OL LON SI ONY 702 21 12313 102 11 GINMO NOLLVAYOINI ABVI3IHdOHd SNIVINOD 133HS SIHL EH OUO gt c gt gt jo ESSES lt S LoS lt OG oj 259 5 T g S Ola 955 582 a OO gt Dg lt 5 c E o c o dg o 5 lt gt ot FEL ea SEALS OS c gE S e 0 5 1 00 549000 SX c 1 ooSgt ZzQcoEsdl a DOL ISe W uinjeu DOL J893se A DOL 4 1 DOL JSE W unge DOL uono2es 03 UINJOY DOL 03 unge DOL 03 DOL UNY o 5 Q rc n o 2 2
64. INCOLN 8 ELECTRIC PULSE WIDTH TIME PERIOD control signal is applied to the base of the transis tor module to turn on the device Varying of this pulse width controls the output current of the machine See Figure E 8 THERMAL SENSOR There is a thermal sensor in the torch head to pro tect it from abusive use If the thermal sensor is tripped the SAFETY LED will light and the machine will not function This thermal sensor interrupts the safety circuit which prompts the con trol board to prevent output from the machine and signal the status board to light the SAFETY LED Wait for the torch to cool and reset the safety cir cuit PRO CUT 60 LINCOLN NOTES PRO CUT 60 E 7 DOL ISe W DOL J893se A DOL 4 1 DOL JSE W DOL gt 5 oj DOL uonoes 03 uum DOL uonoes 03 DOL uonoes oj TABLE OF CONTENTS Section F TROUBLESHOOTING amp REPAIR SECTION F 9 9 Troubleshooting amp Repair Section F Safety Precautions s sirena F 1 9 How to Use Troubleshooting Guide sessi 1 PC Board Troubleshooting Procedures sse enne F 2 Troubleshooting F 3 F 11 Control and Power Board Connector F 1
65. IT TEST CONTROL RELAY CR2 HIGH VOLTAGE TRANSFORMER HIGH FREQUENCY BOARD FIGURE F 12 High Voltage Test Component Locations TEST PROCEDURE NOTE This test can be performed best with alligator clips used with the meter probes NOTE This test requires that the torch trigger be pulled to activate the circuit Be sure to use an isolated meter because of the high voltage and high frequency pro duced 1 Connect input power to the machine 2 Turn ON OFF Power Switch to OFF Test A Test for 115 VAC primary voltage to High Frequency Transformer 1 Locate and connect probes to leads 35 and 31 on Control Relay CR2 Use alligator clips for best results See Figure F 12 LINCOLN amp ELECTRIC 2 Turn ON OFF Power Switch to ON 3 Pull the torch trigger to close Control Relay CR2 contacts 115 VAC will be present for only ONE SECOND when the torch trigger is pulled NOTE When using an analog meter the pointer will deflect to approximately 20 VAC This is normal 4 Turn ON OFF Power Switch to OFF a If the 115 VAC primary voltage is not present Control Relay CR2 or the Control Board could be faulty Replace F 32 PRO CUT 60 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC FE au nile 818 EJE Bi o iac Return to Section TOC Return to Master TOC F 33 TROUBLESHOOTING amp REPAIR HIGH VOLTAGE TRANSFOR
66. ITIVE PROBE EXPECTED TO TERMINAL TO TERMINAL RESISTANCE MARKED MARKED 40 4 500 ohms or higher TABLE F 1 Transistor Module Resistance Tests Return to Section TOC Return to Master TOC PRO CUT 60 Return to Section Return to Master TOC Return to Section TOC lux nile 818 EJE Bi o Return to Section Return to Master TOC Return to Master TOC F 23 PRO CUT 60 11 TROUBLESHOOTING amp REPAIR TRANSISTOR MODULE TEST Replace the terminal screw snugly a little more than finger tight The Transistor Module is mounted behind the Power Board and the terminal screw completes the electrical connection Perform the following resi tance tests listed in Table 1 NOTE Meter lead polarity must be observed for these resistance tests a lf a low resistance is measured in both polarities the transistor module is shorted Replace the transis tor module the Power Board and the Control Board If a high resistance is measured in both polarities the transistor module is open Replace the transistor module the Power Board and the Control Board 12 Replace all leads MOUNTING a Torque screws to 17 in Ibs 1 9 N M Lv6 1 FIGURE F 9 Transistor Module Test Points LINCOLN amp ELECTRIC Return to Section Return to Master TOC Return to
67. L uonoes TABLE OF CONTENTS Section C ACCESSORIES SECTION 9 4A 5 5 8 55 0 2 22 2204 24 Tua Pen REDE E Pun EURO Section C an 3 p 199 1 1 19 1 HARE C 1 0 ac Return to Master TOC o 0 gt yp c 5 Return to Master PRO CUT 60 1 ACCESSORIES OPTIONS ACCESSORIES DRAG CUP ASSEMBLY S241 14 The drag cup protects the torch by preventing the torch from touching the workpiece SHIELD CUP ASSEMBLY S24162 This shields the torch tip and provides more visibil ity to the workpiece than the drag cup Note the shield cup does not prevent the torch tip from touching the workpiece Return to Section TOC Return to Master TOC TORCH SPARE PARTS KIT K872 Included with each machine Includes O 8 st Shield Cup Asmbly S24162 9 g2 8 8 Nozzles gt ole 035 0 9mm Orifice S18497 1D EJE 042 1 1mm Orifice S18497 2D E 9 052 1 3mm Orifice S18497 3D 078 Gouging 2 0mm Orifice S18497 4D Electrode 187520 Drag Asmbly 24114 Wrench 18808 19576 1 These parts come in a 5 pack olo O10 S5 o 5 2 2 Return to Section Return to Master TOC 3 99 PRO CUT 60 TABLE OF CONTENTS Section D MAINTENANCE SECTION F 9 du pei
68. M15883 3CA EARTH GROUND CONNECTION SINGLE PHASE PRO CUT 60 POWER BOARD NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is provided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine PRO CUT 60 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Flr CIS iz gle 5 ply oO x a Return to Section TOC Return to Master TOC 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
69. MER AND CIRCUIT TEST Test B Test Resistance of High Voltage Transformer Primary 1 PRO CUT 60 Disconnect input power to machine Turn ON OFF Power Switch to OFF Perform the CAPACITOR DISCHARGE PROCEDURE Locate and touch probes to lead 31 and lead 35 on the Control Relay CR2 Resistance should be 4 ohms a If 4 ohms resistance is not measured replace the High Voltage Transformer Test C Test Resistance of High Voltage Transformer Secondary 1 Perform Test B Steps 1 2 amp 3 if needed 2 Locate the two white leads soldered into the two black doughnut chokes located below the High Frequency Transformer See Figure F 12 3 Touch the probes to the two white leads Resistance should be about 12 500 ohms a If approximately 12 500 ohms is not measured replace the High Voltage Transformer Test D Test Chokes L501 and L502 for continuity 1 Perform Test B Steps 1 2 amp 3 if needed 2 Touch probes to each side of the black chokes located below the High Frequency Transformer Resistance should be 10 ohms continuity a If continuity is not measured chokes are open Replace LINCOLN amp ELECTRIC Return to Section Return to Master TOC Return to Section TOC Return to Master TOC lu nile 818 EJE Bi o iac Return to Section TOC Return to Master TOC LINCOLN amp ELECTRIC TROUBLESHOOTING amp REPAIR
70. NOTE Unshaded areas of Block Logic Diagram are the subject of discussion PRO CUT 60 LINCOLN E ELECTRIC Return to Section Return to Master TOC Return to Section TOC Return to Master TOC 5 nile 818 EJE 21 Return to Section TOC Return to Master TOC THEORY OF OPERATION E 2 FIGURE E 3 Output Rectification Control and Feedback TORCH TRIGGER amp OUTPUT SAFETY CIRCUIT CONTROL STATUS BOARD 115VAC CONTROL SCR DIODE BRIDGE OUTPUT RECTIFICATION CONTROL AND FEEDBACK The AC output from the main transformer sec ondary is rectified through the SCR DIODE bridge The machine output is controlled through the transistor module The output current is sensed at the shunt as a low voltage signal and fed back to the control board The control board compares the commands of the output control potentiometer with the shunt feedback signal and the appropriate pulse width modulated PWM control signal is sent to the power board The power board converts the PWM control signal 115VAC FEEDBACK HIGH VOLTAGE TRANSFORMER CIRCUIT TRANSFORMER TRANSISTOR MODULE into an isolated drive signal This isolated signal drives the transistor module to the optimum level to obtain the desired machine output current The control and power board also generate the gate firing pulses for the SCR DIODE bridge The rec tified and controll
71. O GROUND PER NATIONAL 77 PER NATIONAL ELECTRICAL CODE ELECTRICAL CODE m Jm mhe mem m m m TO SUPPLY 257829255 38 2 2 5 LINES JT fa Tb PURGE RUN SWITCH PURGE IS OPEN 1 gt D 319 2 ia enu 324 x15e J2 AIR 323 kt6 22 335 SOLENOID 31 321 p 14 J8 J10 ss Cr 5 Kc CONTROL BOARD i 2 lt O 3 TO GROUND ie PER NATIONAL PRIMARY J3 ELECTRICAL CODE Return to Master TOC e rr o 4 w 2 ac THERMOSTAT ks 46 9 lt re 3 2 PRESSURE 12 1 3 1 4 A Hp 222 3 2 810 39201121 2 25 558 RW 9384 sas SANA J4 J7 J2 J10 J21 J5 J9 J12 3321 386383 J20 J22 L502 1 1 5 1 6 1 8 a 3 80 306 m t v IIT 6 10 7 12 9 16 4 _ LO 3 J3 J6 J8 9 p CONNECTOR CAVITY NUMBERING SEQUENCE 02 316 82 ANY Poo VIEWED FROM COMPONENT SIDE OF BOARD AMPHENOL J olo 1 1 460 575V MAIN TRANSFORMER 6 4 gien i HT zr b TO SUPPLY d LI wi 4 PS i r 1 5 6 I 8 24VAC 1 ed EE TORCH BOTTOM BULKHEAD E o PRI 6 TVA 1 HI FREQ CONNECTOR els a ASBLY ele 2 2 l 72 T PILOT B
72. OC 2 Perform Capacitor Discharge Procedure Perform the following daily 1 Check that no combustible materials are in the cutting or gouging area or around the machine 2 Remove any debris or materials that could block the air flow to the machine for cooling Return to Section TOC Return to Master TOC 3 Inspect the torch cable for any slits puncture marks in the cable jacket kinks or any condition that could restrict air flow to the torch Repair or replace when needed A WARNING To avoid receiving a high frequency shock keep the torch and torch cables in good condition Perform the following every three months or sooner Q O H ks 0 41 gt 4 c 5 a 1 Check air regulator filters weekly in dirty environments 5 9 E 9 4 k 42 ac a If clogged or dirty replace them Return to Section TOC Return to Master TOC PRO CUT 60 4 PRO CUT 60 MAINTENANCE n A 6 6 6 VW FIGURE D 2 General Assembly Exploded View amp HIGH FREQUENCY BOARD ASSEMBLY BASE ASSEMBLY CONTROL PANEL ASSEMBLY CAPACITOR BANK CASE FRONT ASSEMBLY CASE BACK ASSEMBLY INPUT BOX ASSEMBLY LINCOLN amp ELECTRIC DOL ISe W 03 uinjeu DOL 4 21 DOL JSE W 03 uino DOL 4 1 03 UINJY DOL 03 UINJOY 1 0 DOL u0on2es 03 UIN Y 1 gt 5 0
73. R AND CIRCUIT TEST A WARNING Service and repair should be performed only by Lincoln Electric factory trained per sonnel Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and pre cautions detailed throughout this manual Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 216 383 2531 or 800 833 9353 WELD A WARNING HIGH VOLTAGE HIGH FREQUENCY CAN DAMAGE TEST EQUIPMENT Return to Section TOC Return to Master TOC TEST DESCRIPTION This test will identify any problems or faults in the High Voltage Transformer MATERIALS NEEDED Isolated Volt Ohmmeter Multimeter with alligator clips analog meter only PRO CUT 60 Wiring Diagrams lu nile 818 EJE Bi o iac Return to Section TOC Return to Master TOC PRO CUT 60 Return to Section Return to Master TOC Return to Section TOC FE au nile 818 EJE Bi o iac Return to Section TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING amp REPAIR HIGH VOLTAGE TRANSFORMER AND CIRCU
74. Return to Master TOC Return to Section TOC Return to Master TOC FE au nile 818 EJE is Bi iac Return to Section TOC Return to Master TOC G 3 ELECTRICAL DIAGRAMS G 3 BYPASS BOARD SCHEMATIC DIAGRAM M15603 kK lt LU eo e en ox NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is provided for reference only Lincoln Electric dis courages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine LINCOLN 3 PRO CUT 60 SPATE d 9 5 2 5 egtogo pol 2 5 CN gz amp x 828 co 20012 555 Lm QJILVNWN3H2S 70874274 SSVdA8 iS 1 09 1n2 0Ud NOLL23NNOO NOWNOD 031312345 3S1MN3H1O SSIINN AO0P VI 530010 H38WDN 3002 NOWNOD Y ONIAVH STOYLNOD 30 AHLIDOHIO HO Lco o o lt NOLJNNOS ZZ 3oNnOS ATddns W3HOd 03141934S 3S
75. Return to Section Return to Master TOC Return to Section TOC Return to Master TOC 5 TER 818 EJE Bi o iac Return to Section TOC Return to Master TOC F 39 PRO CUT 60 TROUBLESHOOTING amp REPAIR POWER BOARD REMOVAL MOUNTING SCREWS 176 1 quvoa FIGURE F 14 Power Board Removal Replacement REMOVAL REPLACEMENT PROCEDURE 1 Disconnect input power to the machine Remove the Left Case Side Assembly Perform the CAPACITOR DISCHARGE PROCEDURE Remove the Molex Plugs J20 J21 and J22 from the Power Board 5 Remove G1 G2 40 amp B lead spade lugs from the terminals on the SCR modules See Figure F 14 Remove the two C leads the NEG lead and the two 40 leads by unscrewing the terminal screws with a Phillips head screw driver See Figure F 14 Remove leads H1 and H2 by unscrewing the terminal screws with a Phillips head screw driver See Figure F 14 LINCOLN amp ELECTRIC Return to Section Return to Master TOC Return to Section TOC Return to Master TOC 9 AM o n 9 HM oc Return to Section TOC Q O H f 0 41 gt 5 Return to Master LINCOLN TROUBLESHOOTING amp REPAIR POWER BOARD REMOVAL Remove the four mounting Phillips head screws holding the Power Board to the SCR module
76. SVM104 A PRO CUT Single Phase For use with machines having Code Numbers 9819 10096 10112 10118 10217 10218 10393 10394 Return to Master TOC View Safety Info 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 thoughttul operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful Return to Master TOC View Safety Info Le 91 gt gjo 3 al SERVICE MANUAL 150 9002 ctured Under a Quality Program Certified by ABS Quality Evaluations Inc do ISO 900 iui CERTE CATE MEER LINCOLN World s Leader in Welding and Cutting Products ELECTRIC Premier Manufacturer of Industrial Motors Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com Return to Master TOC View Safety Info Return to Master Return to Master TOC Q O ks 7 4 gt 4 c 5 5 ac Return to Master TOC SAFETY i A WARNING PROTECT YOURSELF AND OTHERS FROM POSSIBL
77. T F Pe c gt TK IW a 1 00 144007 gt gt 5 5 0 lt 5 5 5 5 el 285 9 a Re 1N4007 ina 2 W 7 o b lise gt gt 5 o Ble 072 o v 1N5406 o is c gt 5 PRESSURE SWITCH 2 OF SAFETY e gt gt gt o 5 o o j 92 1 2 OF 2 4 ERS pz 2 5 a Be Pn f 94528 o d GENERAL INFORMATION PURGE RUN SWITCH 148 Wu PRESSURE 2 PLACES LABELS o SUPPLY SOURCE POINT J COMMON CONNECTION In Electr FILE G1951 4HB In Electr ger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine Inco ONENTS OR CIRCUITRY L Inco TO STATUS BD THERMOSTAT Return to Section TOC Return to Master TOC c o a o 2 D 9 gt A c E A
78. T LED is blinking The be due to not enough ventila be faulty Replace See machine has no output tion Make certain that the wiring diagram machine s air intakes and Check leads 321 and exhaust louvers are not 322 for loose or faulty con blocked or restricted Allow nections at plug J8 on the machine to cool Control Board The machine s duty cycle If no loose or faulty wiring is may have been exceeded found the Control Board Allow machine to cool and could be faulty Replace modify cutting process Return to Section TOC Return to Master TOC The MALFUNCTION or 1 Check the torch consumables The torch and cable FAULT LED is lit to see if they are melted assembly could be faulty machine has no output together or are touching each other Clean or replace Assembly and Turn the machine off and on again If the FAULT LED will The Power Board could be Return to Section TOC Return to Master TOC not stay off when you try to faulty Perform Powe cut there is a failure within the machine THE MACHINE Perform SHOULD NOT BE LEFT ON Test The Control Board could be Replace the torch and cable faulty Replace assembly Test When the torch trigger is pulled 1 Check Torch Consumables The Transistor Module the OUTPUT ON LED lights 2 Check for proper Air Pres could be faulty Perform for a very short period of time sure the Transistor Module Test The pilot arc is unusually bright
79. They are also called inverse time or thermal magnetic circuit breakers DO NOT use fuses or circuit breakers with a lower amp rating than recommended This can result in nuisance tripping caused by inrush current even when machine is not being used for cutting or gouging at high output currents Use input and grounding wire sizes that meet local electrical codes or see the Specifications page in this manual GROUND CONNECTION Ground the frame of the machine A ground ter minal marked with the symbol Ly is located at the left side of the Input Box Assembly Access to the Input Box Assembly is at the top rear of the machine See your local and national electrical codes for proper grounding methods INPUT POWER SUPPLY CONNECTIONS A qualified electrician should connect the input power supply leads to the L1 and L2 terminals on the Input Box Assembly Terminal Block 1 Follow all national and local electrical codes 2 Follow Input Supply Connection Diagram located on the inside of the access door 3 Use a single phase line or one phase of a three phase line 4 Connect leads to machine s terminal block See Figure A 2 a For 8 AWG wire 8 4mm connect leads directly to machine s terminal block LINCOLN B 4 b For 10 AWG wire 5 3mm connect leads to terminal block using the ferrules S19117 1 provided 1 Strip 1 2 12 7mm of insulation from wire 2 Place ferrule over wire 3 Connect to
80. VAL REPLACEMENT 6 Loosen the four screws on the PROCEDURE plastic frame These screws go through the Case Front 1 Disconnect input power to the Assembly into the line machine switch When the screws no longer engage the line switch 2 Perform the remove the line switch so it can DISCHARGE PROCEDURE be worked on 7 Remove and save the electrical 3 Remove the Right Case Side tape The electrical tape will be Assembly by removing the sheet re applied during assembly metal screws 8 Remove leads T1 T2 L1 amp L2 4 Remove the black ON OFF Power Switch knob and plastic 9 Install new ON OFF Power insert by unscrewing the small Switch in reverse order of screw in the center of the knob removal Be sure to re apply Remove from the shaft See electrical tape to switch Figure F 13 5 Remove the face plate by PRO CUT 60 squeezing the two tabs together and sliding the plate off See Figure F 13 LINCOLN 8 ELECTRIC Return to Section Return to Master TOC Return to Section TOC Return to Master TOC nile 818 EJE Bi o iac Return to Section TOC Return to Master TOC LINCOLN amp ELECTRIC TROUBLESHOOTING amp REPAIR F 36 CONTROL BOARD REMOVAL A WARNING Service and repair should be performed only by Lincoln Electric factory trained per sonnel Unauthorized repairs performed on this equipment could result in danger to the technician or the machine oper
81. WELD CAUTION If the Case Back Assembly is removed a restraining strap must be used so the panel cannot be completely removed until the fan motor leads are disconnected Failure to do this could cause damage to the fan motor or fan motor leads Return to Section TOC Return to Master TOC REMOVAL REPLACEMENT DESCRIPTION This procedure will assist you in removing or replacing the fan blade and fan motor in case of a faulty motor or broken fan blade MATERIALS NEEDED FE au nile 818 EJE Bi o iac Strap to keep Case Front Assembly from falling open 5 16 Nut driver Screw driver 11 32 Open end wrench Wire cutter Pliers Return to Section TOC Return to Master TOC PRO CUT 60 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC FE au nile 818 EJE Bi iac Return to Section TOC Return to Master TOC F 47 PRO CUT 60 TROUBLESHOOTING amp REPAIR FAN BLADE AND FAN MOTOR REMOVAL REPLACEMENT BRACKET MOTOR FIGURE F 17 Fan Blade amp Fan Motor REMOVAL REPLACEMENT PROCEDURE NOTE See Figure F 17 1 2 Disconnect input power to the machine Perform the CAPACITOR DISCHARGE PROCEDURE Disconnect the air line to the air regulator on the Case Back Assembly Remove the Case Back Assembly Access Door Disconnect the input power supply leads from the terminal block 6 R
82. as not timed out the pilot arc lights immediately If postflow air has timed out after 20 sec onds air preflows for two seconds before pilot arc lights If the arc is not transferred by bringing plasma in contact with the work with in 2 5 seconds the pilot arc shuts off 9 Make a 10 Stop cutting by releasing the torch trigger Arc stops Postflow air continues for 20 seconds To continue cutting repeat Step 8 11 Turn ON OFF POWER SWITCH to OFF when job is done If the SAFETY LED glows at any time during oper ation check the following Torch consumables are assembled properly Machine will not start if they are not properly in place Nozzle condition The nozzle must be clean After the problem is corrected or no problem is found press the SAFETY RESET button If SAFETY LED goes out machine is ready for use If SAFETY LED continues to glow refer to the TROUBLESHOOTING GUIDE in the TROU BLESHOOTING AND REPAIR SECTION of this manual for a recommended course of action CUTTING PROCEDURE RECOMMENDATIONS For best results use proper cutting or gouging procedures Plasma arc cutting is a very eco nomical process when used properly Improper procedures or equipment use will result in poor quality work and high operating costs The follow ing procedures will help you get maximum perfor mance from your PRO CUT 60 PRO CUT 60 OPERATION Use Pilot Arc Properly The pilot arc transfers
83. at acdsee F 3 F 52 Electrical Section G Parts Manual E P 184 PRO CUT 60 TABLE OF CONTENTS Section A INSTALLATION SECTION E 2 Page E installation Section A Technical Specifications 1 5 Safety A 2 Select Proper A 2 Ee T A 2 o mer HQ A 2 High Frequency Interference Protection 0 0 444404 A 2 Input Electrical T Fuses and Wire cn 4 ee 4 g Input Power Supply 4 Air Input 5 B Reconnect Procedure equ Med UU SE SINE CARN A 6 8 Output Connections 7 a Q O ks 7 4 gt 4 c 5 5 ac Return to Master TOC LINCOLN PRO CUT 60 Return to Section Return to Master TOC Return to Section TOC 5 nile 818 EJE DIH ic Return to Section TOC Return to Master TOC Return to Master TOC A 1 INSTALLATION TECHNICAL SPECIFICATIONS PRO CUT 60 INPUT SIN
84. at would have to be replaced Bright 2 5 second timed pilot arc Purge Run switch Two independent mechanisms for sensing a shorted torch Needed for safety and torch protection Patented safety sensor monitors if torch parts are in place Latching safety circuit mechanism requires that the operator reset the circuit Exposed torch parts voltage monitoring with safety shutdown Built in undercarriage for portability Built in air controls including air pressure regulator Air line filtering Preflow Afterflow timing Preflow stops if cutting or gouging resumes in previous afterflow Easy to use torch trigger switch Line voltage compensated Thermostatically protected Solid state overcurrent protection PRO CUT 60 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC FE E lu 5 gt 818 EJE 57 Biz wv iac Return to Section TOC Return to Master TOC B 3 Works with pure nitrogen for cutting non ferrous metal e Smart switching of pilot contactor so that it does not switch under load Low fan noise at idle Modular construction for easy servicing CUTTING AND GOUGING CAPABILITY The PRO CUT 60 is rated at 60 amps 115 VAC at 6096 duty cycle on a 10 minute basis or 45 amps 115VAC at 100 duty cycle If the duty cycle is exceeded a thermal protector will shut off the output of the machine until it cools to the
85. ator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and pre cautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 216 383 2531 or 800 833 9353 WELD CAUTION Printed Circuit Boards can be damaged by static electricity REMOVAL REPLACEMENT DESCRIPTION This procedure will assist you in removing or replacing the Control Board MATERIALS NEEDED Phillips head screw driver Static grounding strap Replacement Control Board PRO CUT 60 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC FE la 5 nile 818 EJE 5 5 Bi o iac Return to Section TOC Return to Master TOC F 37 PRO CUT 60 TROUBLESHOOTING amp REPAIR CONTROL BOARD REMOVAL REMOVAL REPLACEMENT PROCEDURE 1 Disconnect input power to the machine Remove the Left Case Side assembly Perform the CAPACITOR DISCHARGE PROCEDURE Remove the seven Molex plugs from their headers and position out of the way See Figure 1 Remove the 10 screws mounting Remove the Control Board from the machine by carefully lifting it straight up until clear of all other parts Insert the replaceme
86. aulty Perform the able Assembly and frequency spark is not present at the spark gap check that pilot control relay CR2 contacts close when the torch trigger is pulled a pilot control relay CR2 contacts close when torch trigger is pulled per form b If pilot control relay CR2 contacts DO NOT close test for 115 VAC between leads 36 and 31 on pilot control relay CR2 when the torch trigger is pulled If 115 VAC IS pre sent pilot control relay CR2 could be faulty Replace If 115 VAC IS NOT pre sent check plug J10 on Control Board and asso ciated wires for loose or faulty connections If none are found Control Board could be faulty Replace CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216 383 2531 or 1 800 833 9353 LINCOLN 8 ELECTRIC Return to Section TOC Return to Master TOC PRO CUT 60 TROUBLESHOOTING amp REPAIR F 6 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC lx nile 818 EJE Bi The air begins to flow the OUTPUT ON
87. cal codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations LINCOLN SAFETY lii FOR ENGINE ELECTRIC AND MAGNETIC powered equipment FIELDS 7 a Turn the engine off before troubleshooting and maintenance 5 be dangerous work unless the maintenance work requires it to be running 8 a Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding or 7 b Operate engines in open well ventilated cutting current creates EMF fields around welding or areas or vent the engine exhaust fumes cutting cables and welding machines outdoors M b EMF fields may interfere with some pacemakers and welders or cutters having a pacemaker should consult their physician before welding or cutting Return to Master TOC Exposure to EMF fields in welding or cutting may have other 7 c Do not add the fuel near an open flame health effects which are now not known welding or cutting arc or when the engine is running Stop the engine and allow it to cool All welders or cutters should use the following procedures in before refueling to prevent spilled fuel from order to minimize exposure to EMF fields from the welding vaporizing on contact with hot engine parts or cutting circuit and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not
88. ct s deux machines soud er 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 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 zones l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer 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
89. d Turn ON OFF Power Switch to ON a If 12 VAC is NOT present check Plug J22 for loose or faulty wiring b If no loose or faulty wiring is found perform Transformer Test Turn ON OFF Power Switch to OFF F 28 PRO CUT 60 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC nile 818 EJE Bi Return to Section Return to Master TOC F 29 PRO CUT 60 TROUBLESHOOTING amp REPAIR POWER BOARD TEST Test B Test for 7 VDC signal between Power Board and Control Board NOTE This test requires that the torch trigger be pulled to activate the circuit Be sure to use an isolated meter because of the high voltage and high frequency produced NOTE This test requires testing DC voltages Polarity must be observed 1 Locate and insert probes into the following Power Board plug locations See Figure 11 a Insert the NEGATIVE probe into Plug 4J22 lead 332 lead cavity b Insert the POSITIVE probe into Plug 2J22 lead 338 lead cavity 2 Turn the ON OFF Power Switch to ON 3 Pull torch trigger When air pre flow times out and the pilot arc is established 7 VDC should be present 4 Release torch trigger Turn ON OFF Power Switch to OFF a If 7 VDC is NOT present check Power Board Plug J22 and Control Board Plug J6 for loose or faulty wiring b If no loose or faulty wiring is fou
90. dental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding and cutting arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding or cutting out of posi tion or in confined places Always wear safety glasses with side shields when in a welding or cutting area Connect the work cable to the work as close to the welding or cutting area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding or cutting current passing through lifting chains crane cables or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail 4 h Also see item 7c PRO CUT 60 CYLINDER may explode
91. do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 216 383 2531 or 800 833 9353 WELD A WARNING HIGH VOLTAGE HIGH FREQUENCY CAN DAMAGE TEST EQUIPMENT Return to Section TOC Return to Master TOC TEST DESCRIPTION This test will identify any problems or faults in the Power Board MATERIALS NEEDED Isolated Volt Ohmmeter Multimeter analog only This test has the potential to damage test equipment PRO CUT 60 Wiring Diagrams FE au nile 818 EJE Bi o iac Return to Section TOC Return to Master TOC PRO CUT 60 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC 5 TER 818 EJE Bi o iac Return to Section TOC Return to Master TOC TROUBLESHOOTING amp REPAIR POWER BOARD TEST MOUNTING SCREWS Lv6 1 FIGURE F 11 Power Board Test Points TEST PROCEDURE 1 Connect input power to machine 2 2 Turn ON OFF Power Switch to OFF Test A Test for 12 VAC voltage to Power Board 1 Locate and insert probes into Power Board Plug locations 1J22 lead H4 and 3J22 lead H3 See Figure F 11 3 Carefully insert the probes into the lead cavity to make contact with the lea
92. ds 2 6 Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays 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 23 FUMES AND GASES can be dangerous 40 3 a Welding or cutting may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding or cutting keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding or cut ting with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel 3 b Do not weld or cut in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating products Shielding gases used for arc weldin
93. e operation section The MALFUNCTION or FAULT LED starts blinking during cutting or gouging Pilot arc is OK but cutting will not establish arc CAUTION CUTTING PROBLEMS Make sure the torch con sumables are tight and are in good condition Replace if necessary Check the air supply for oil or water contamination If there is oil or water present the air supply must be fil tered or the machine switched to nitrogen bottled air Make sure air pressure is 60 to 65 PSI Check spark gap setting 060 clean if necessary This is an overcurrent con dition caused by a surge of current the machine is not designed to handle Release the torch trigger and resume cutting or gouging Check torch consumables for wear replace if neces sary Make sure work cable and clamp are secure Clean any painted or heavily corroded work surfaces Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION 1 Perform The torch and cable assembly could be faulty Perform the Torch Torch Cable Assembl and Internal Trigger and Safet Circuit Tests Check Pilot Resistor R2 See Wiring Diagram The Control Board could be faulty Replace Check Jump Start Diode see wiring diagram Perform the Torch Cable Assembl and Internal Trigger and Safety C
94. ed DC voltage is filtered by the output capacitors and choke and is applied to the machine s torch and work terminals The control board also operates the status board and com mands the pilot arc circuitry NOTE Unshaded areas of Block Logic Diagram are the subject of discussion LINCOLN amp ELECTRIC PRO CUT 60 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC 5 nliz 818 EJE Bi iac Return to Section TOC Return to Master TOC E 3 THEORY OF OPERATION FIGURE E 4 High Voltage High Frequency and By Pass Circuit TORCH TRIGGER amp OUTPUT SAFETY CIRCUIT CONTROL STATUS BOARD 115VAC CONTROL BOARD AIR SOLENOID 115VAC LINE SWITCH RECONNECT SCR DIODE BRIDGE HIGH VOLTAGE HIGH FREQUENCY AND BY PASS CIRCUIT The control board passes the 115vac through the CR2 relay contacts to the primary of the high volt age transformer The secondary of the high volt age transformer delivers a high voltage to the spark gap generator and also to the high frequen cy transformer The high frequency transformer transfers the high frequency spark to the 115VAC FEEDBACK HIGH VOLTAGE TRANSFORMER CIRCUIT HI FREQ TRANSFORMER TRANSISTOR MODULE torch terminal This momentary burst of high fre quency is used to ignite the pilot arc The by pass board is necessary to prevent any unwanted signals from interferin
95. emove the six screws from the Case Back Assembly There are two screws at the top and four at the bottom After the last screw is removed be prepared to use a strap or other support to keep the Case Back Assembly from falling open The motor leads could be pulled out of their con nectors if this should happen Unscrew the brass air line con nector from the male elbow using pliers or channel locks Remove the brass air line con nector and companion nylon compression fitting LINCOLN 8 ELECTRIC Return to Section Return to Master TOC Return to Section TOC Return to Master TOC 9 AM o n 9 HM oc Return to Section TOC Q O H f 0 41 gt 5 Return to Master LINCOLN amp ELECTRIC 9 Remove the fan blade TROUBLESHOOTING amp REPAIR FAN BLADE AND FAN MOTOR REMOVAL REPLACEMENT Pull the rubber air line hose into the machine out of the rubber grommet Be sure to keep the Case Back Assembly support ed Allow it to lean out away from the machine at about a 45 angle so you have plenty of room to work on the fan blade and fan motor Note fanblade position on motor shaft for reference when replacing fan a Loosen the fan blade clamp using a slot head screw driver or 5 16 nut driver Do not completely unscrew the clamp b Slide the fan blade and clamp off the motor sha
96. eraux dans les PRO CUT 60 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 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 LINCOLN 8 ELECTRIC RETURN TO MAIN INDEX MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page SY et iv instalation Section A Technical Specifications 1 1 Safety 2 Select Proper Location aaia aa aE E 2 High Frequency Interference A 2 Input Electrical Connections A 3 2 cto RA 6 OUTPUT Connections reed rn am xa Pe ke e EAR A 7 Reese ne iene Section Operating INStruCtIONS ertt rrr bv eden pete Era tuia B 1 Safety Precauttoris 2 er RE rri a XX RES e ERR B 1 Ge
97. es are within the specified range SWITCH THERMOSTAT WIRE GUN TRIGGER ELECTRODE FIGURE 5 and Cable Wiring Diagram INTERNAL TRIGGER AND SAFETY CIRCUIT TEST PROCEDURE 1 Turn the PRO CUT 60 ON OFF Power Switch to OFF Disconnect input power supply to machine Remove the roof and the Right and Left Case Side Assemblies using a 5 16 nut driver Perform the CAPACITOR e DISCHARGE PROCEDURE Disconnect the connector 4 pin Locate Plug J5 on the Control Board See and for the location of the Control Board and Plug J5 recepta Locate the 4 pin cle See Figure 6 location PRO CUT 60 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC FE au nile 818 EJE Bi iac Return to Section TOC Return to Master TOC F 19 PRO CUT 60 TROUBLESHOOTING amp REPAIR TORCH TORCH CABLE ASSEMBLY INTERNAL TRIGGER AND SAFETY CIRCUIT TEST Disconnect Plug J5 from its header on the Control Board Test for zero ohms continuity from the following test points on Plug J5 header to the 4 pin leads on the bulkhead of the machine See Pin 4J5 lead 4 to 4 pin pin 4 Pin 3J5 lead 2 to 4 pin pin 2 Pin 6J5 lead 336 to 4 pin pin 1 Pin 8J5 lead 337 to 4 pin pin 3 a any of the above tests do not agree with the expected no
98. eturn to Section Return to Master TOC Return to Section TOC nile 818 EJE iac Return to Section TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING amp REPAIR SCR MODULE REMOVAL SOCKET HEAD CAP SCREWS TORQUE TO 35 IN LBS 3 9 N M REMOVAL REPLACEMENT PROCEDURE NOTE See Figure F 16 1 Disconnect input power to the machine Remove the Left Case Side assembly Perform the CAPACITOR DISCHARGE PROCEDURE Perform the POWER BOARD REMOVAL PROCEDURE SCR MODULES FIGURE F 16 SCR Module Location with Power Board Removed 5 Remove the two socket head cap screws of the top SCR module using a 4mm Allen type wrench Remove the SCR module from the heat sink Remove the second SCR mod ule following Steps 5 and 6 Install the replacement SCR Modules Procedure is the same for both SCR modules a Clean the heat sink surface with 000 fine steel wool PRO CUT 60 F 44 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC FE au nile 818 EJE 5 5 Bi o iac Return to Section TOC Return to Master TOC F 45 PRO CUT 60 TROUBLESHOOTING amp REPAIR SCR MODULE REMOVAL b Rinse the heat sink surface with alcohol or acetone Apply a 002 to 005 coat of joint compound evenly to the heat sink mounting surface and
99. ft 13 when See Step reinstalling the fan 11 Remove the fan motor a Loosen and remove the two nuts flat washers and lock washers from the motor mounting bracket using an 11 32 open end wrench When the motor is free from the mounting bracket place it carefully on the bottom of the machine 12 Install 13 Install fan 14 Reassemble the b Remove the Case Back Assembly c Out the wire wraps bundling the motor leads d Cut the motor leads or remove the wire connectors to remove the motor replacement motor in reverse order of removal blade When installing the fan blade be sure the clamp is placed on the motor side of the shaft a Slide the fan 25 past the end of the shaft and tighten the clamp b Spin the fan to be sure it is free to rotate remaining components in reverse order of removal F 48 PRO CUT 60 49 TROUBLESHOOTING amp REPAIR TORCH HEAD REMOVAL REPLACEMENT A WARNING Service and repair should be performed only by Lincoln Electric factory trained per sonnel Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and pre cautions detailed throughout this manual Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are u
100. g or cutting 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 employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer 3 e Also see item 7b PRO CUT 60 Return to Master Return to Master TOC Q ks 7 41 gt 4 c 5 5 Return to Master SAFETY WELDING OR CUTTING we SPARKS can cause fire or explosion 4 a Remove fire hazards from the welding or cut ting area If this is not possible cover them to prevent the welding or cutting sparks from start ing a fire Remember that welding or cutting sparks and hot materials from welding or cutting can easily go through small cracks and openings to adjacent areas Avoid welding or cut ting near hydraulic lines Have a fire extinguisher readily available Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard 249 1 and the operating information for the equipment being used When not welding or cutting make certain no part of the electrode circuit is touching the work or ground Acci
101. g with the Pro Cut 60 circuitry NOTE Unshaded areas of Block Logic Diagram are the subject of discussion PRO CUT 60 LINCOLN E ELECTRIC Return to Section Return to Master TOC Return to Section TOC 5 TER 818 EJE Bi iac Return to Section TOC Return to Master TOC Return to Master TOC THEORY OF OPERATION FIGURE E 5 Pilot Arc TORCH TRIGGER amp OUTPUT SAFETY CIRCUIT CONTROL STATUS BOARD 115VAC AIR SOLENOID CONTROL 115VAC 115VAC LINE SWITCH RECONNECT SCR DIODE BRIDGE PILOT ARC The Pro Cut 60 has a smooth continuous pilot arc The pilot arc is a means of establishing and transferring the arc to the work piece for cutting The pilot arc current flow is from the positive potential work terminal through the R2 resistor and CR2 contacts to the pilot lead circuit in the torch cable The pilot current transfers from the NEGATIVE POTENTIAL 115VAC HIGH VOLTAGE TRANSFORMER CIRCUIT FEEDBACK IR HI FREQ TRANSFORMER TORCH TRANSISTOR MODULE nozzle to the electrode in the torch head and then on to the torch bulkhead connector which is con nected to the negative potential within the machine When the torch head is brought close to the work piece the pilot arc transfers to the work surface and the cutting arc is established This transition takes place because of the low resis tance between the torch electrode and t
102. he work piece TORCH BULKHEAD m CONNECTOR ELEGQTRODE A NOZZLE POSITIVE WORK TERMINAL E R2 HH cro 1 CIRCUIT FIGURE E 6 Pilot Lead Circuit LINCOLN amp ELECTRIC NOTE Unshaded areas of Block Logic Diagram are the subject of discussion PRO CUT 60 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC FE au nile 818 EJE Bi o iac Return to Section TOC Return to Master TOC E 5 THEORY OF OPERATION FIGURE E 7 Transistor Switching Operation EMITTER BASE DRIVH CURRENT TRANSISTOR SWITCHING OPERATION A transistor is a solid state device consisting of three layers of silicon crystal These three layers form the emitter collector and base regions of a transistor They are used at high frequencies in high power applications and switching circuits When used as a switch the transistor will be turned on collector current flow when there is PRO CUT 60 COLLECTOR CURRENT COLLECTOR adequate base drive current Likewise the device will be turned off no collector current when there is insufficient base drive current The tran sistor allows the control of a large amount of cur rent flow through the collector and emitter with a much smaller current in the base circuit See Figure E 7 LINCOLN 8 ELECTRIC Return to Section
103. hould begin to flow and AIR PRESSURE LED should turn on Return to the RUN mode If air does not flow when the torch trig ger pulled consult your local Lincoln Authorized Field Service Facility Check torch consumables replace if necessary 1 With 60 PSI applied to the machine the air pressure switch should be closed Check for continuity less than 1 ohm between leads 319 to 323 See wiring diagram Check the air solenoid SV1 operation by apply ing 115 VAC to the solenoid leads a If the solenoid activates and air flows the solenoid is good b If the solenoid does not activate replace the solenoid Check plug J10 on the Control Board for loose or faulty connections The Control Board could be faulty Replace If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216 383 2531 or 1 800 833 9353 LINCOLN 8 ELECTRIC PRO CUT 60 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC nile 818 EJE Bi WV iac Return to Section TOC Return to Master TOC F 11 TROUBLESHOOTING GUIDE TROUBLESHOOTING amp REPAIR The arc starts but sputters badly If cutting expanded metal condition may be nor mal se
104. idable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding or cutting cable and welding or cutting machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 4 c and 6 LINCOLN ELECTRIC ARC RAYS can burn 2 a Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or cutting or observing open arc welding or cutting Headshield and filter lens should conform to ANSI 787 standar
105. ine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and pre cautions detailed throughout this manual Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 216 383 2531 or 800 833 9353 WELD CAUTION Printed Circuit Boards can be damaged by static electricity Return to Section TOC Return to Master TOC REMOVAL REPLACEMENT DESCRIPTION This procedure will assist you in removing or replacing the Transistor Module MATERIALS NEEDED 5mm Allen type wrench Static grounding strap Replacement Transistor Module Joint Compound Lincoln T12837 or equivalent Dow Corning 340 Replacement Power Board FE au nile 818 EJE Bi o iac Return to Section TOC Return to Master TOC PRO CUT 60 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC FE au 5 TER 818 EJE Bi iac Return to Section TOC Return to Master TOC TROUBLESHOOTING amp REPAIR TRANSISTOR MODULE REMOVAL REMOVAL REPLACEMENT PROCEDURE NOTE It is recommended that when the Transistor Module is replaced the Power Board and the Control Board should be
106. ion Return to Master TOC Return to Section TOC Return to Master TOC Q 5 o 2 2 Return to Section o O HF gt 4 o 9 4 c i 5 gt Return to Master TOC OPERATION Gouging Metal 1 Set the OUTPUT CURRENT CONTROL to maximum 2 Use the plasma torch with a 524114 Drag Cup assembly or a S24162 shield cup 3 Bring the torch slowly towards the work piece at a 30 angle but do not pierce the work piece Do not touch the nozzle to the work piece See Figure B 3 a Blow molten metal away from the torch b If needed raise the air pressure to approximately 75 psi to help blow away molten metal c This process will blow a lot of molten metal and dross BE CAREFUL Blow the dross away from the torch away from the operator and away from flammable objects d Do not allow the torch cable or body to contact hot surfaces e Performance is similar to air carbon arc gouging with a 1 8 3 2mm carbon electrode LINCOLN 8 ELECTRIC B 8 ANGLE OF APPROACH TORCH HELD AT 30 ANGLE THROUGHOUT GOUGE ANGLE MAINTAINED THROUGHOUT GOUGE FIGURE B 3 Gouging Metal 3 99 PRO CUT 60 LINCOLN NOTES PRO CUT 60 B 9 DOL ISe W DOL J893se A DOL 4 1 DOL JSE W uino DOL gt 5 oj DOL uonoes 03 uum DOL uonoes 03 DO
107. ion for more than five seconds the arc shuts off and the machine goes into postflow c The pilot arc duty cycle is 20 seconds out 80 seconds f the torch trigger is continuously pulled and released to obtain a bright continuous arc the duty cycle limit will be reached and the arc will be turned off for the duty cycle limit When the arc is turned off the OUTPUT ON and FAULT LEDs flash alternately 3 99 PRO CUT 60 OPERATION Cutting Thick Sections of Metal 1 Set the OUTPUT CURRENT CONTROL above the mid range Red position a Use the minimum current needed to make a satisfactory cut Hold the torch nozzle about 1 8 3 2mm from the cutting surface Do not let the torch nozzle touch the work or carry a long arc a Use the 24114 Drag Cup to protect the torch b Use only the 052 1 3mm or the 042 1 0mm nozzles Do not use the 035 0 8mm nozzle for cutting thick sections of metal Start the cut from the edge of the work piece when possible Pierce the work piece by slow ly lowering the torch onto the metal at a 30 angle This will blow the dross away from the torch tip Slowly rotate the torch to vertical position as the arc becomes deeper See Figure B 2 Keep moving while cutting Cut at a steady speed without pausing TORCH AT 30 ANGLE TO PIERCE ROTATE TO 90 ANGLE TO CUT FOR CUTTING FIGURE B 2 Cutting Thick Piece of Metal LINCOLN 8 ELECTRIC Return to Sect
108. ir since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine PRO CUT 60 LINCOLN Return to Section TOC Return to Master TOC Return to Section Return to Master TOC Return to Section TOC Return to Master TOC FE au nile 818 EJE 5 5 Bi o iac Return to Section TOC Return to Master TOC ELECTRICAL DIAGRAMS G 11 STATUS PC BOARD M15601 Item bee 6i x Identification e dr RESISTOR MF 1 2W 470 296 LED1 LED3 LED T 1 3 4 GREEN HLMP 3502 LED2 LED5 LED6 LED T 1 3 4 RED HLMP 3003 LED4 LED T 1 3 4 YELLOW HLMP 3400 CONNECTOR 8 PIN MOLEX CONNECTOR NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is provided for reference only Lincoln Electric dis courages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine LINCOLN 3 PRO CUT 60 12 ELECTRICAL DIAGRAMS BYPASS PC BOARD M15603 Return to Section TOC Return to Master TOC M15603 pl
109. ircuit Tests the Module Test Perform the The Control Board could be faulty Replace Perform Transistor Module Perform Power Board Test If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216 383 2531 or 1 800 833 9353 PRO CUT 60 LINCOLN 8 ELECTRIC TROUBLESHOOTING amp REPAIR F 12 CONTROL BOARD CONNECTOR LOCATION Return to Section TOC Return to Master TOC ASVHd ATONIS 09 L 10 Oud 8 5 7 5 6 5 5J5 J4 J5 4 5 FIGURE F 1 Control Board Connector Locations POWER BOARD CONNECTOR LOCATION Return to Section TOC Return to Master TOC MOUNTING SCREWS 176 1 u3MOd B G2 69 4 20 24207 420 59 2 nile 818 EJE Bi o iac Return to Section TOC Return to Master TOC FIGURE F2 Power Board Connector Locations PRO CUT 60 13 TROUBLESHOOTING amp REPAIR CAPACITOR DISCHARGE PROCEDURE AWARNING Service and repair should be performed only by Lincoln Electric factory trained per sonnel Unauthorized repairs performed on this equipment could result in danger to the technician or the machine ope
110. machine terminal block c Tighten screws to 16 in Ibs 1 8 TERMINAL BLOCK RECONNECT PANEL ASSEMBLY For 10 5 3mm 50 AWG Wire Only 12 7 Strip 10 5 3mm Wire L L 3 Place Ferrule S19117 1 Over Wire as Shown Before Insertion into Machine Terminal Block FIGURE A2 Input Power Supply Connections PRO CUT 60 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC FE au nile 818 EJE Bi iac Return to Section TOC Return to Master TOC A 5 INSTALLATION AIR INPUT CONNECTIONS Supply the PRO CUT 60 with clean compressed air or nitrogen e Supply pressure must be between 70 psi and 120 psi 482 kPa and 827 kPa Flow rate should be approximately 4 7 133 NOTE in the air supply to the PRO CUT 60 can cause severe problems Use only a clean air supply 1 Connect the air supply to the PRO CUT 60 regulator a Remove the plastic thread protector from the machine s regulator input port located on the back of the machine Refer to figure A 1 The input port is a 1 4 6 3mm NPT thread b Connect the air supply to the machine reg ulator with an appropriate gas connection fitting Sealing the connection with Teflon tape is recommended 2 Tighten the air fitting connection to prevent leakage Do not overtighten NOTE When using nitrogen gas from
111. ment B 2 Operational Features and Controls 2422 B 2 Design Features and Advantages B 2 Cutting and Gouging Capability sse B 3 E B 3 Controls and SONOS 3 E Operating Steps ee m B 4 5 Cutting Procedure Recommendations B 5 gt 5 E Cutting and Gouging B 5 i Cutting Thin c Me m B 6 Cutting Expanded 2 7 Cutting Thick 7 Go ging Maelal iones dina rds RE Rp E a iE B 8 Q O ks 7 4 gt 4 c 5 5 ac Return to Master TOC PRO CUT 60 1 OPERATION SAFETY PRECAUTIONS Read and understand entire section before operating machine WARNING oe ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet clothing Return to Section TOC Return to Master TOC Insulate yourself from work and ground Always wear dry insulating gloves FUMES AND GASES 23 can be dangerous M 0 Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone p o Eus E
112. nable to perform the tests repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 216 383 2531 or 800 833 9353 WELD REMOVAL REPLACEMENT DESCRIPTION This procedure will assist you in the replacing torch head components that need to be repaired because of a safety pilot or trigger circuit problem Return to Section TOC Return to Master TOC MATERIALS NEEDED Phillips head screw driver 13mm wrench supplied with the machine FE au nile 818 EJE Bi o iac Return to Section TOC Return to Master TOC PRO CUT 60 TROUBLESHOOTING amp REPAIR F 50 TORCH HEAD REMOVAL REPLACEMENT Return to Section TOC Return to Master TOC 9 4 CONNECTOR S ELECTRODE LEAD PILOT LEAD PHILLIPS HEAD SCREW HANDLE SAFETY LEADS BRASS COMPRESSION NUT CABLE STRAIN RELIEF ALIGNMENT HOLE Return to Master TOC E S p o n 9 oc ele 5 5 9 p FIGURE F 18 Torch Head Removal Replacement REMOVAL REPLACEMENT b Remove the one sheet metal PROCEDURE screw on the left hand side 8 E of the access door and a x NOTE See Figure F 18 swing open the door 1 Disconnect input power to the C Test for a voltage across the machine stud marked WORK and the bulkhead connector brass 2 Perform the fitting NO voltage should z be present If a voltage is
113. nd the Power Board or the Control Board could be faulty Replace Test C Test for 1 0 VDC to 1 5 VDC Base Voltage to Transistor Module NOTE This test requires that the torch trigger be pulled to activate the circuit Be sure to use an isolated meter because of the high voltage and high frequency produced NOTE This test requires testing DC voltages Polarity must be observed 1 Locate and insert probes into the following Power Board plug locations See Figure 11 a Insert the NEGATIVE probe into Plug 2J20 lead 40 lead cavity b Insert the POSITIVE probe into Plug 1J20 lead B lead cavity 2 Turn the ON OFF Power Switch to ON 3 Pull torch trigger When air pre flow times out and the pilot arc is established 1 0 VDC to 1 5 VDC should be present 4 Release torch trigger Turn ON OFF Power Switch to OFF a If this voltage IS present or an_ incorrect voltage is present perform TRANSISTOR MODULE b If transistor module test is OK then the Power Board could be faulty Replace LINCOLN 8 ELECTRIC Return to Section Return to Master TOC Return to Section TOC Return to Master TOC FE au nile 818 EJE 5 gt Bi iac Return to Section TOC Return to Master TOC TROUBLESHOOTING amp REPAIR POWER BOARD TEST Test D Test for 0 2 VDC to 0 3 VDC Gate Drive Voltages to the SCR Module NOTE This test requires tha
114. ne It also specifies the appropriate test procedure to verify that the subject com ponent 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 specified 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 do not understand the test procedures are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical trou bleshooting assistance before you proceed call 216 383 2531 or 1 800 833 9353 CAUTION HIGH VOLTAGE HIGH FREQUENCY can damage test equipment LINCOLN amp ELECTRIC Return to Section Return to Master TOC Return to Section TOC lu nile 818 EJE Bi o Return to Section Return to Master TOC Return to Master TOC LINCOLN amp ELECTRIC TROUBLESHOOTING F 2 PC BOARD TROUBLESHOOTING PROCEDURES AWARNING ELECTRI
115. neral DESCHPUOM 2 Recommended Processes and B 2 Operational Features and Controls sse B 2 Design Features and Advantages sse nennen B 2 Cutting and Gouging Capability essen B 3 e 3 Controls Settings te rete E B 3 Peri B 4 Cutting Procedure Recommendations 2 B 5 tur n Section C ACGOSSOLIGS ic tere oet adt C 1 Section D Safety Precautions m D 1 Routine and Periodic D 1 VIEW el t EE eer eg rne ug rn D 2 Theory of Operation 1 11ire cer rtt vececescupcesentcccvaccvschepcresnsencucucexe Section E Power Supply Operation nennen nnns E1 E 5 DOR Operation e E 6 Thermal PEOIGCHOF sex ERE NE E 7 Troubleshooting and nnne nnns Section F How Use Troubleshooting 0 04000 1 PC Board Troubleshooting Procedures F 2 Troubleshooting Guide 4 i
116. ng procedure See Figure A 4 for the location of torch and work connections Connect cutting torch to machine A 4 See Figure 1 Turn OFF Power Line switch 2 Disconnect input power to the machine 3 Insert the torch cable into the machine through the cable boot 8 a Insert enough torch cable to make all connections 4 Turn and lock strain relief clamp 1 onto bolt to secure the gas line 5 Connect the gas line fitting to the brass union and tighten with a wrench 6 Connect to pilot lead 5 to terminal marked PILOT 7 Connect work lead 7 to terminal marked WORK 8 Connect 4 pin connector 2 PRO CUT 60 INSTALLATION Pilot Lead Bolt Work Lead Cable Boot Strain Relief Clamp 4 Pin Connector Bulkhead Connector Brass Fitting Gas Line FIGURE A 4 Connect Torch Cable To Machine Connect work clamp to work clamp cable which extends from the front of the machine See Figure 5 1 Insert the cable through the hole at the end of the work clamp handle 2 Pull the work clamp cable through the hole until it reaches the nut and bolt assembly 3 Tighten the nut and bolt FIGURE A 5 Connect Work Clamp LINCOLN TABLE OF CONTENTS Section B OPERATION SECTION g 9 RT rr Section B Safety alice MR B 1 E General Description M B 2 Recommended Processes and Equip
117. nt Control Board carefully into the machine and install in reverse order of removal Be sure to re connect the seven Molex plugs back into their headers securely LINCOLN 8 ELECTRIC Return to Section Return to Master TOC Return to Section TOC Return to Master TOC FE au nile 818 EJE Bi o iac Return to Section TOC Return to Master TOC LINCOLN amp ELECTRIC TROUBLESHOOTING amp REPAIR F 38 POWER BOARD REMOVAL A WARNING Service and repair should be performed only by Lincoln Electric factory trained per sonnel Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and pre cautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 216 383 2531 or 800 833 9353 WELD CAUTION Printed Circuit Boards be damaged by static electricity REMOVAL REPLACEMENT DESCRIPTION This procedure will assist you in removing or replacing the Power Board MATERIALS NEEDED Phillips head screw driver 7 16 Nut driver Static grounding strap Replacement Power Board PRO CUT 60
118. 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 fol lowed when warranty reports are to be sub mitted NOTE Following this procedure and writing on the warranty report INSTALLED AND SWITCHED PC BOARDS TO VERIFY PROB LEM will help avoid denial of legitimate PC board warranty claims PRO CUT 60 F 3 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC lu nile 818 EJE Bi WV aic Return to Section TOC Return to Master TOC PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION Major Physical or Electrical Damage is Evident No LEDs light when the ON OFF Power Switch 1 turned ON Machine is dead Fan is not running CAUTION OUTPUT PROBLEMS Contact The Lincoln Electric Service Dept 216 383 2531 or 1 800 833 9353 WELD Make sure input voltage corresponds to machine nameplate voltage Make sure the reconnect panel is configured properly for the input voltage being applied to the PRO CUT 60 Single Phase Check the input line fuses Replace if blown Make sure ON OFF Power Switch S1 is operating properly Check the main transformer primary leads
119. operly locat ing installing and maintaining the machine can reduce or eliminate the effects of high frequency interference or the loss of high frequency machine operating power The following procedures should be followed to minimize interference to the following areas the machine the cutting leads feedback into the power lines ungrounded metallic objects 1 Make the power supply lines as short as possible 2 Enclose power supply lines entirely in rigid metallic conduit or equivalent shielding a Provide a good electrical ground between the conduit and the machine b Connect both ends of the conduit to a driven ground c Entire conduit length should be continuous NOTE The machine frame must be grounded The work terminal ground DOES NOT ground the machine frame PRO CUT 60 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC 9 E 9 4 p ac Return to Section TOC Q O H f 0 4 gt 5 Return to Master A 3 3 Connect the work terminal to a ground within ten feet of the machine a Use grounding cable that is the same size as or larger than the work cable b Make grounding cable as short as possible c Connect the ground tightly d Useone of the following ground methods 1 Connect to a metal underground water pipe that is in direct con
120. ow SAFETY LED The SAFETY LED glows when there is an operating problem with the machine torch or torch consumables 4 OUTPUT CURRENT CONTROL The OUT PUT CURRENT CONTROL adjusts the cur rent flow for maximum cutting results See User Chart Range guide on machine s name plate for recommended range settings based on thickness of steel being cut ON OFF POWER SWITCH machine ON or OFF Turns the LINCOLN E ELECTRIC Return to Section Return to Master TOC Return to Section TOC Return to Master TOC c 9 T o 4 I Return to Section TOC Q O 0 41 gt 4 c pus Return to Master OPERATION B 4 CODENO SERIAL NO MACHINE ON OUTPUT ON AIR PRESSURE THERMAL FAULT PUSH TO RESET SAFETY UW PRO CUT 60 PLASMA CUTTING SYSTEM 1 Safety Reset Button 4 Output Current Control RATED OUTPUT VOLTS Co MAX DCV _ DC AT RATED INPUT VOLTAGE 2 Purge Run Switch 5 ON OFF Power Switch INPUT HERTZ vors RATED OUTPUT AMPS USER CHART RANGE STEEL THICKNESS THE LINCOLN ELECTRIC COMPANY CLEVELAND OHIO USA 3 Status LED Display FIGURE B 1 Control Panel Keys OPERATING STEPS When preparing to cut or gouge position the machine as close to the work as possible Make sure you have all materials needed to complete
121. p or because of noise If the circuit can be reset it is OK to continue Maintain proper stand off while cutting 10 to 15 Too long a stand off may cause nuisance safety trips Check torch consumables Replace if needed Replace the torch and cable assembly Check plug J7 located on the Control Board and associated wires for loose or faulty connections Check Plug J9 on Status Board and J8 on Control Board for loose or faulty connections Test for 24 VAC between leads C2 and H6 plug J7 on Control Board Refer to wiring diagram a the 24 VAC IS NOT present or voltage is very low the main transformer could be faulty Perform b If the 24 VAC is present at leads C2 to H6 the Control Board could be faulty Replace The torch cable assembly may faulty Torch Torch Cable Assembly Internal Trigger and Safety Circuit Check for continuity zero ohms between leads 336 and 337 from the torch 4 pin connector on the machine to plug J5 on the Control Board Refer to wiring diagram Check Pilot bleed resistor R3 Normal is 40 ohms See wiring diagram The control board could be faulty Replace Perform If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216 383 2531 or 1 800 83
122. pment Do not touch electrically hot parts e Always connect the PRO CUT 60 ground ing terminal located on the side of the Case Back Assembly to a good electrical earth ground e Turn the PRO CUT Power Switch OFF when connecting power cord to input power SELECT PROPER LOCATION Place the PRO CUT 60 where clean air can freely circulate in through the front intake and out through the rear louvers Dirt dust or any foreign material that can be drawn into the machine should be kept at a minimum Not following these precautions can result in the nuisance shutdown of the machine because of excessive operating temperatures The location or improper 2 of E machine could affect the operation o electronic equipment See the HIGH FREQUEN CY INTERFERENCE PROTECTION Section for more information STACKING The PRO CUT 60 cannot be stacked LINCOLN 8 ELECTRIC A 2 TILTING The PRO CUT 60 must be placed on a stable level surface using the attached undercarriage so it will not topple over HIGH FREQUENCY INTERFERENCE PROTECTION Locating installing or maintaining the PRO CUT 60 incorrectly could cause interference with prop er radio TV or electronic equipment operation and result in poor cutting and gouging perfor mance The spark gap oscillator in the machine s high frequency generator generates electrical sig nals like a radio transmitter that can cause high frequency interference Therefore pr
123. r mal resistance specifications then Plug J5 on the Control Board the torch 4 pin receptacle or the associated wiring must be repaired b If all of the above tests are within the normal resistance specifications continue with test procedure Re connect Plug J5 back into its header Test for 24 VAC between Pin 5J5 lead C1 and Pin 745 lead 335 on Plug J5 a Carefully insert the volt ohm Multimeter probes into the back of the J5 plug into pin cavity 5J5 lead C1 and pin cavity 7J5 lead 335 See Figure F 1 16 Disconnect b Connect input PRO CUT 60 power to c Tum ON OFF Power Switch to ON d Read meter If 24 VAC is NOT present continue with test procedure 12 Turn ON OFF Power Switch to OFF 13 Disconnect main input power to machine 14 Perform the CAPACITORI DISCHARGE PROCEDURE 15 Check Plug J10 and Plug J5 and associated wiring for loose or faulty connections Plug J10 from Header J10 17 Test for continuity zero ohms between 3J10 and 6J10 on Control Board Header J10 a If continuity is not indicated the Control Board could be faulty 18 Perform MAIN TRANSFORMER TEST 19 Replace the Control Board if all of the above tests are within normal specifications LINCOLN amp ELECTRIC TROUBLESHOOTING amp REPAIR F 20 TORCH TORCH CABLE ASSEMBLY INTERNAL TRIGGER AND SAFETY CIRCUIT TEST Return to Section TOC Return to Mas
124. rator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and pre cautions detailed throughout this manual Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 216 383 2531 or 800 833 9353 WELD A WARNING Return to Section TOC Return to Master TOC Failure to follow this capacitor discharge procedure can result in electric shock PROCEDURE DESCRIPTION This procedure must be performed before any test or removal procedure that does not require the machine to be electrically hot MATERIALS NEEDED High resistance high wattage resistor 25 1000 ohms 25 watts minimum Insulated pliers Insulated gloves DC Volt Ohm meter Multimeter lu nile 818 EJE Bi o iac Return to Section TOC Return to Master TOC PRO CUT 60 TROUBLESHOOTING amp REPAIR F 14 CAPACITOR DISCHARGE PROCEDURE Qio 5 olg PROCEDURE 6 Touch the resistor leads across 9 the two capacitor straps as 5 NOTE See Figure F 19 shown for 10 seconds c E 5 1 Disconnect input power to the a DO NOT TOUCH THE 2c machine CAPACITOR STRAPS WITH YOUR HANDS OR ANY 2 Remove the Left Case Side OTHER PART OF YOUR Assembly BO
125. reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216 383 2531 or 1 800 833 9353 PRO CUT 60 Return to Section TOC Return to Master TOC TROUBLESHOOTING amp REPAIR F 10 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 3 nile 818 EJE Bi iac Return to Section TOC Return to Master TOC The MACHINE ON LED is lit but there is no response when the torch trigger is pulled The AIR PRESSURE LED does not turn on The fan runs nor mally The FAULT LED blinks CAUTION AIR FLOW PROBLEMS Check the air supply to the machine Make sure suffi cient air pressure is supplied to the PRO CUT 60 If the air does not flow the machine will not operate Low air pressure will also result in a no start condi tion With the machine in PURGE adjust the air reg ulator to 60 psi 413kPa minimum while air is flowing AIR PRESSURE LED must be lit when the air is flowing Check the operation of the air solenoid by switching the machine to PURGE If the air pressure is sufficient the air s
126. replaced NOTE See Figure F 15 1 2 e 3 4 TRANSISTOR MODULE Disconnect input power to the machine Remove the Left Case Side assembly Perform the CAPACITOR DISCHARGE PROCEDURE Perform the POWER BOARD REMOVAL PROCEDURE SOCKET HEAD CAP SCREWS TORQUE TO 26 IN LBS 2 9 N M FIGURE F 15 Transistor Module loca tion with Power Board Removed 5 Remove the two socket head LINCOLN cap screws from the Transistor Module using the 5mm Allen Type wrench 6 Remove the Transistor Module from the heat sink Install the Transistor Module replacement a Clean the heat sink surface with 000 fine steel wool b Rinse the heat sink surface with alcohol or acetone c Apply a 002 to 005 coat of joint compound evenly to the heat sink mounting surface and the Transistor Module mounting surface Use Lincoln Joint Compound T12837 equivalent such as Dow Corning 340 d Press the Transistor Module onto the heat sink surface Remove the module to make sure enough joint compound has been applied When removed both surfaces should have an even texture with no bare spots f this even textured look does not appear re apply the joint compound e Mount the Transistor Module on the heat sink with the 5mm socket head screws to 26 in
127. se procedures for the best operating results Failure to follow these procedures can cause interference and machine performance problems INPUT ELECTRICAL CONNECTIONS Before installing the machine check that input supply voltage phase and frequency are the same as the machine s voltage phase and fre quency as specified on the machine s rating plate on the Case Front Assembly See Figure A 1 for the location of the machine s input cable entry opening terminal block and reconnect panel assembly Input power supply entry is through the hole in the Case Back Assembly FIGURE 1 Case Back Assembly 1 Input Supply Cable Entry Opening 2 Terminal Block 3 Reconnect Panel Assembly 4 Air Pressure Regulator LINCOLN amp ELECTRIC Return to Section Return to Master TOC Return to Section TOC Return to Master TOC amp 9 E Ja 5 per ac Return to Section TOC Q O H ks 0 41 gt 4 c 5 5 Return to Master INSTALLATION FUSE AND WIRE SIZES Protect the input circuit with the super lag fuses or delay type circuit breakers listed on the Specifications page of this manual for the machine being used The tripping action of delay type circuit breakers decreases as the magnitude of the current increases
128. t the torch trigger be pulled to activate the circuit Be sure to use an isolated meter because of the high voltage and high frequency produced NOTE This test requires testing DC voltages Polarity must be observed 1 Locate and insert probes into the following Power Board plug locations See Figure F 11 a Insert the NEGATIVE probe into Plug 1J21 lead 383 lead cavity b Insert the POSITIVE probe into Plug 3J20 lead G2 lead cavity 2 Turn the ON OFF Power Switch to ON 3 Pull torch trigger When air pre flow times out and the pilot arc is established 0 2 VDC to 0 3 VDC should be present 4 Release torch trigger 5 Locate and insert probes into the following Power Board plug locations See Figure 11 a Insert the NEGATIVE probe into Plug 1J21 lead 383 lead cavity b Insert the POSITIVE probe into Plug 4J20 lead G1 lead cavity 2 Turn the ON OFF Power Switch to ON 3 Pull torch trigger When air pre flow times out and the pilot arc is established 0 2 VDC to 0 3 VDC should be present 4 Release torch trigger Turn ON OFF Power Switch to OFF a If specific voltages ARE NOT present check Power Board Plugs J20 and J21 and Control Board Plug J6 for loose or faulty wiring b If no loose or faulty wiring is found the Power Board Control Board or SCR module could be faulty Replace PRO CUT 60 31 TROUBLESHOOTING amp REPAIR HIGH VOLTAGE TRANSFORME
129. tact with earth for ten feet or more 2 Connect to 3 4 19mm galvanized pipe or a 5 8 16mm solid galvanized iron steel or copper rod driven at least eight feet into the ground NOTE Do Not use the building frame electri cal conduit or a long pipe system for ground ing the machine This could result in increased high frequency interference NOTE When the machine is used in a metal building drive several good earth grounds around the edge of the building Use the method in 2 above 4 Enclose all electrical conductors within 50 feet 15 2m of the machine in grounded rigid metallic conduit or equivalent shielding a Do not use flexible metallic conduit 5 Make work and torch leads as short and as close together as possible a Lead length should not exceed 50 feet 15 2m b Tape leads together when possible 6 Check torch and work cable rubber insulation coverings to be sure they do not have any cracks or cuts that could result in high fre quency leakage that could interfere with other electronic equipment PRO CUT 60 INSTALLATION a Use insulated work cables with a high natural rubber content such as the Lincoln Stable Arc cables These better resist high frequency leakage than neoprene or other synthetic rubber insulated cables 7 Keep the torch in good repair and all connec tions tight to reduce high frequency leakage 8 Keep all access panels and covers tightly closed Follow the
130. ter TOC CONTROL PC BOARD 4 PIN RECEPTACLE Return to Section TOC Return to Master TOC 4 PIN RECEPTACLE IN BULKHEAD 3 nile 818 EJE is Bi iac ASVHd 3 19NIS 09 L 10 OHd J5 E N J8 FIGURE F 7 Control Board and 4 Pin Connector Test Points PRO CUT 60 Return to Section TOC Return to Master TOC 21 TROUBLESHOOTING amp REPAIR TRANSISTOR MODULE TEST A WARNING Service and repair should be performed only by Lincoln Electric factory trained per sonnel Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and pre cautions detailed throughout this manual Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 216 383 2531 or 800 833 9353 WELD TEST DESCRIPTION This test will identify any problems or faults in the Transistor Module Return to Section TOC Return to Master TOC POWER PC BOARD FE au nile 818 EJE Bi o iac FIGURE F 8 Power Board Location Return to Section TOC Return to Master TO
131. to the re connect panel for loose or faulty connections Check the leads from the ON OFF Power Switch S1 to the reconnect panel T1 and T2 for loose or faulty connections Perform The main transformer could be faulty Check for an open or grounded primary winding If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216 383 2531 or 1 800 833 9353 PRO CUT 60 LINCOLN 8 ELECTRIC Return to Section Return to Master TOC Return to Section TOC Return to Master TOC E 5 TER 818 EJE Bi iac Return to Section TOC Return to Master TOC TROUBLESHOOTING amp REPAIR F 4 TROUBLESHOOTING GUIDE PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION Observe Safety Guidelines detailed in the beginning of this manual No LEDs light when the ON OFF Power Switch is turned ON Machine is dead Fan runs normally The MACHINE ON LED is lit and the SAFETY LED is lit CAUTION OUTPUT PROBLEMS Make sure input voltage corresponds to machine nameplate voltage Make certain the reconnect panel is configured properly for input voltage being applied to PRO CUT 60 Push the SAFETY RESET button the LED should go out This circuit sometimes trips on power u
132. ue test procedure Right Case Side Assembly Torch Cable Access Door 23 22 Strain Relief Clamp Q 4 Pin Connector Bulkhead Connector Brass Fitting Gas Line Pilot Lead Bolt Hole Work Stud Work Lead Cable Boot FIGURE F 3 Torch Cable Connections PRO CUT 60 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC 5 9 E 9 4 p ac Q O H 0 41 gt 5 F 17 TROUBLESHOOTING amp REPAIR TORCH TORCH CABLE ASSEMBLY INTERNAL TRIGGER AND SAFETY CIRCUIT TEST Disconnect the trigger lead 4 pin connector by unscrewing it Disconnect the electrode lead using a 9 16 open end wrench to remove the brass adaptor fit ting attached to the bulkhead connector Disconnect the pilot lead by removing the wing nut marked PILOT Remove only the pilot lead Do not remove any of the leads below the brass nut Rotate and lift the torch cable strain relief clamp to remove it from the bolt head Do not remove the strain relief clamp from around the three leads Pull the trigger lead electrode lead and pilot lead bundled in the strain relief clamp out of the machine through the rubber boot 5 Move the torch cable assembly to a convenient work area Perform the following resistance tests using a volt ohm meter Multimeter See
133. y electrically live parts at the same time Tools which come in contact with the P C Board must be either conductive anti static or static dissipative Remove the P C Board from the static shielding bag and place it directly into the equipment Don t set the P C Board on or near paper plastic or cloth which could have a sta tic charge If the P C Board can t be installed immediately put it back in the static shielding bag the P C Board uses protective shorting jumpers don t remove them until installation is complete If you return a P C Board to The Lincoln Electric Company for credit it must be in the static shielding bag This will prevent further damage and allow proper failure analysis 4 Test the machine to determine if the failure symptom has been corrected by the replacement PC board NOTE It is desirable to have a spare known good PC board available for PC board trou bleshooting NOTE Allow the machine to heat up so that all electrical components can reach their oper ating temperature 5 Remove the replacement PC board and substitute it with the original PC board to recreate the original problem a If the original problem does not reappear by substituting the original board then the PC board was not the problem Continue to look for bad connections in the control wiring harness junction blocks and terminal strips b If the original problem is recreated by the substitution

Lincoln Electric SVM104-A User's Manual

Contents

Download Pdf Manuals

Related Search

Related Contents