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Lincoln Electric SVM140-A User's Manual

Contents

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3. 2 s13aso 93 osmeees 11 farso soes 475 oc __ ______516668 9 __ ___ _
4. Olio O ITEM REQ D PART NO DESCRIPTION c 1 513430 92 3300 50 C2 C8 10 C 13 C 14 C 17 C20 31 516668 5 022 50 o C23 C24 C29 C31 C34 C35 OIG C36 C37 C39 C40 C4 1 C47 gt C53 C55 C58 C63 C64 C65 9 C66 C68 C69 C73 C74 C75 olo C3 1 513490 121 1000735 2 gt C4 C18 2 513490 63 47750 C5 1 513490 71 100750 c C6 1 T11577 52 0047 or 0057 1400 gt C7 1 513490 72 50750 1 513490 93 27735 C15 C 16 C32 C33 C42 5 516668 11 1750 C15 C25 C50 3 513490 25 4 7735 C21 C26 C28 C30 C54 C57 8 513490 42 1 0735 C62 C71 C22 C43 C44 3 516668 9
5. olo O O ae WIRING DIAGRAM PRO CUT 55 0 10 9 9 RIGHT SIDE OF MACHINE c 5 2 PER oc N A rr Sc 720 Nacsa PW XD S E M F lt 3 lt 56 3 1 RM 207 i 203A 206 s 2 POWER 64 j BRIDGE rov N 205 H 209 gt 6 U 4 61 i S3 2 208 Di _ CO Di 501 505 422 L J21 PSI SET RESET VOLT FC 7502 v AUXILIARY 277B POWER VR 3 503 E aw p 204 201 110 221 Rc K i CURRENT oe ales TRANSFORMER eS 212 4 13 Low Psi LED T 9 202A 207A 218 rorween 0 9 207 P XFMR N 213 9 1 502 VOLT N 21 9 a GND 9 1200 450 L 7501 1 505 TDO d M 21444 9 merma D c c ji N 210 3n RESET LED ul 212 215 esi itu Q 213 9 v A R 214 4 lt 5 O W 219 2 275 40 E an R m 215 276 H V XFER 223 Q 5 Ww M 2 1 x2 7 8 ELEC SHUNT TWIST EAN Soc 221 1 MOTORS 8210 275 4 5 XFER SHUNT TWIST PR J31 e 276 e iSTHIGGER 2 12 11 TRIGGER 277 9 3 NOZZLE X83 3 3 IGBT
6. 11099 1S0 1521 JOWJOJSUEL ueej6 syejsouueu N si 1591 1515 eui 10595 eJnsseJd jddns 1591 5 1 uuojeg Se qeunsuoo 10 uo un NOL 491Se A 0 uunjeH 901 491Se N 0 uunjeH NOL 0 uunjeH NOL uunjeH 1085990140491 eu TROUBLESHOOTING amp REPAIR y 10 195 si BINS 91 91v 8 031 ev 91 91v LYVHOMO ld ONILOOHSA 1 119 0 F 10 DOL uonoes DOL uonoes 201 201 F 11 LINCOLN amp NOTES PRO CUT 55 F 11 NOL 491Se A 0 uunjeH 901 491Se N 01 uunjeH NOL J91Se AN 0 uunjeH NOL uunjeH DOL uonoes uunjeg DOL uonoes uunjeg DOL DOL Return to Section TOC Return to Master TOC Return to Section TOC Ret
7. gt 018 5 oO Return to Section TOC Return to Master TOC Return to Master TOC F 4 F 4 TROUBLESHOOTING amp REPAIR 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 Major physical or electrical dam Contact your local authorized Contact the Lincoln Electric age is evident when the sheet Lincoln Electric Field Service Service Department 216 383 metal cover s are removed Facility for technical assistance 2531 or 1 888 935 3877 Machine is dead no output no Make sure that the input power 1 Check the input power switch fan no status indicator lights switch is in the ON position 51 for proper operation See Check the input voltage at the the Wiring Diagram machine Input voltage must 2 Check the leads associated match the rating plate and the with the power switch 51 and reconnect panel the auxiliary transformer T2 for loose or faulty connections Check for blown or missing See the Wiring Diagram fuses in the input lines and the 0 6 amp slow blow reconnect 3 Perform the Auxiliary Trans fuse Machine is dead not output no 1 Check the input voltage at the 1 Perform the status indicator lights fans run machine Input voltage must Transformer Test match the rating plate and the 2 Pe
8. Return to Section TOC Return to Master TOC PRO CUT 55 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC O10 O Fle Cc xXx gt 0218 5 4 cc Return to Section TOC Return to Master TOC Return to Master TOC F 52 F 52 TROUBLESHOOTING amp REPAIR CONTROL BOARD REMOVAL AND REPLACEMENT continued 5 Locate the control board and the five molex type plugs connected to it See Figure F 17 6 Carefully remove the five molex type plugs by depressing the locking tabs and gently extracting the plugs from the P C board receptacles FIGURE F 18 CONTROL BOARD REMOVAL FROM MOUNTING PINS CONTROL BOARD 7 Using the needle nose pliers and screwdriv er gently remove the control board from the eight mounting pins by depressing the tabs on the mounting pins and carefully removing the board from the pins See Figure F 18 A CAUTION Be sure to follow the recommended static free methods for handling printed circuit boards Failure to do so can result in permanent damage to the equipment 8 When replacing the control board align the mounting holes with the eight mounting pins and gently slide the PC board onto the mounting pins until the board snaps onto the pins PRO CUT 55 LINCOLN amp 10 11 12 DEPRESS LOCKING TAB ON MOUNTING PIN MOUNTING PIN 8 Replace the five molex t
9. eq e pueu uonouisaJ 10 JO e qeo u2J01 1591 piouejog pue yoo y 44210 seoq 1591 uedoud SI 4210 95 jueuuedeq pue 198109 4966143 un indino pue e oe1deooJ 4910 eu 1 4 695 9 YISH aNu 159 seg OU JJ eseojoJ 1580 01 5 195 SSeJd eq eui H s 037 eju jj euuou Ayne aq spea pue Sjejsouueui YOOUO yo suuni JOU sjeAno ens eye episui pue yo 15 519 suey 1591 pug Aynuyuoy yoo PRO CUT 55 LINCOLN E 1591 1591 19144994 uuojJed euo si q31
10. Return to Master TOC Return to Master TOC O O 4 o gt c 2 Return to Master G 1 ELECTRICAL DIAGRAMS TABLE OF CONTENTS ELECTRICAL DIAGRAMS SECTION Electrical Diagrams Section e Section G Wiring Diagram 208V 230V 460V 110634 G 2 Plasma Output Board Schematic 10722 G 3 Power P C Board Schematic 110616 G 4 Display P C Board Assembly 110721 G 5 Display Board M19920 S G 6 ContolSehemalle G32 G 7 Control P C Board Assembly G3328 1 seen G 8 Control Board Assembly 29929 2 G 9 Output P C Board Assembly 03326 1 G 10 Output P C Board Assembly 03326 2 G 11 Power P C Board Assembly 13172 1 22000000 1 00000 enne nnns G 12 Power Board Assembly 3172 2 G 13 PRO CUT 55 LINCOLN G 1 G 2 ELECTRICAL DIAGRAMS WIRING DIAGRAM ENTIRE MACHINE
11. Return to Section TOC Return to Master TOC PRO CUT 55 LINCOLN amp F 67 F 67 TROUBLESHOOTING amp REPAIR INPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT continued PROCEDURE 5 With the phillips head screw driver remove the lead terminals connected to the rectifier 1 Remove input power to the Pro Cut 55 terminals 2 Perform Filter Capacitor 6 Using the 3 16 allen wrench remove the two Discharge Procedure detailed earlier in this cap head screws and washers mounting the section input rectifier bridge to the center panel 3 Locate the input rectifier and the leads con assembly nected to it See Figure F 25 Return to Section TOC Return to Master TOC 4 Identify and mark the leads connected to the rectifier terminals CAP HEAD 207 MOUNTING SCREW mun Return to Section TOC Return to Master TOC O Fle Cc xXx gt 0218 5 4 cc FIGURE F 25 INPUT RECTIFIER LEAD LOCATIONS Return to Section TOC Return to Master TOC PRO CUT 55 LINCOLN amp F 68 F 68 TROUBLESHOOTING amp REPAIR INPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT continued 7 Carefully remove the input rectifier bridge 8 When installing a new input rectifier apply a thin coating of Penetrox A 13 Heat Sink Compound Lincoln E2529 to the mating surfaces Torque the mounting cap screws
12. gt 0218 5 4 x Return to Section TOC Return to Master TOC Return to Master TOC F 13 F 13 TROUBLESHOOTING amp REPAIR INPUT FILTER CAPACITOR DISCHARGE PROCEDURE continued A WARNING ELECTRIC SHOCK can kill 0 e Have an electrician install and e Turn the input power off at the fuse box before working on equipment Do not touch electrically hot parts e Prior to performing preventative mainte nance perform the following capacitor dis charge procedure to avoid electric shock DISCHARGE PROCEDURE 7 1 Turn off input power and disconnect input power lines 8 2 Remove the 5 16 hex head screws from the wraparound machine cover 3 Be careful not to make contact with the capacitor terminals located in the top and bottom of the Input Power Board 4 service this equipment 5 Obtain a high resistance and high wattage resistor 25 1000 ohms and 25 watts mini mum This resistor is not supplied with machine NEVER USE A SHORTING STRAP FOR THIS PROCEDURE Locate the four capacitor terminals large hex head cap screws shown in Figure F 1 One pair is at the top and one pair is at the bottom of the Power Board Use electrically insulated gloves and insu lated pliers Hold the body of the resistor and connect the resistor leads across the two capacitor terminals Hold the resistor in place for 10 seconds DO NOT TOUCH CAPACITOR TERMINALS WITH
13. O Fle C Ix gt 018 5 4 t cc Return to Section TOC Return to Master TOC PRO CUT 55 LINCOLN amp Return to Section TOC Return to Master TOC Return to Section TOC O Fle Cc gt 0218 5 4 x Return to Master TOC F 47 TROUBLESHOOTING amp REPAIR LOW VOLTAGE CIRCUIT TEST continued FIGURE F 13 OUTBOARD LOW VOLTAGE CIRCUIT TEST POINTS AND LEDs G3326 PRO CUT 55 OUTPUT PRO CUT 55 OUTPUT BOARD LED DEFINITIONS LED1 Red This light indicates that 24 VAC is being supplied to the output board from the aux iliary transformer It also shows that the 24 VAC is being rectified to approximately 28 VDC This DC voltage is used for the parts in place check for the torch circuit LED2 Red This light indicates that 12 VAC is being supplied to the output board from the aux iliary transformer It also shows that the 12 VAC is being rectified to approximately 17 VDC This DC voltage is used to power the trigger circuit and solenoid driver circuits incorporated on the output board LEDS Green This light indicates that the air solenoid driver circuit is functioning When this LED is lit the air solenoid should be activated LED4 Green This light indicates that the trig ger circuit on the output board has been acti vated This LED should be lit when the torch or remote trigger is closed This trigger c
14. NUMEN BENE 0 31 970___ ___ _ 2 Dp ON ALL ANGLES IS 5 OF A DEGREE MATERIAL TOLERANCE v TO AGREE WITH PUBLISHED STANDARDS gt lt NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual G 6 15V gt 021 4 15V Igy AIR SET 15V 140 lt li 3 140 140 L J4 J4 oo 140 5 2090 0 FILENAME MI892 _1AA lt GENERAL INFORMATION mm ROME ELECTRICAL SYMBOLS PER E1537 R 20 021 CAPACITORS MFD 822 5 V UNLESS OTHERWISE SPECIFIED LED 9 RESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED LABELS DIODES 14 400V UNLESS OTHERWISE SPECIFIED SUPPLY VOLTAGE NET POWER SUPPLY SOURCE POINT 57 COMMON CONNECTION FRAME CONNECTION L EARTH GROUND CONNECTION PRO CUT 58 THE LINCOLN ELECTRIC CO TYPE ND OHIO U S A SUBJECT DISPLAY BOARD SCALE SHT R __ M L D pate 18 28 96 V Ms SUP S D C 920 PROCUT 55 ELECTRICAL DIAGRAMS G 7 SCHEMATIC CONTROL PC BOARD 15 ee tp 6 9357 Ip 15 315v l ey 99 184336 GATE DRIVE 4 CUTTING CURRENT lt SETPOINT LOCAL 015 O
15. 1500 OHMS 15 RESISTOR 5 1748 Be 715 E BST TG DRIVER _ Return to Section Return to Master TOC 0 2 Melek Return to Section TOC B Return to Master TOC d G3326 2 PRO CU T 55 OUTPUT O Fle C Ix gt 0218 5 4 cc Return to Section TOC Return to Master TOC NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the LINCOLN ine BE machine PROCUT 55 a ELECTRICAL DIAGRAMS G 12 PC BOARD ASSEMBLY POWER G3172 1 ITEM REQ D PART NO IDENTIFICATION necu new 2 516668 5 022 50 513490 93 27 35 516668 9 150pF 100 13490 130 27 50 14293 18 DPST RELAY m m i 7 Return to Section TOC Return to Master TOC in o I m m D1 D2 D3 D4 D5 D6 D7 D12 0 T12199 1 1N4004 D13 D14 D8 D9 D10 D11 DZ1 DZ5 DZ9 DZ12 4 12702 40
16. T S 8 osa R E EPEE W Y Monee OUTPUT The power board also monitors the filter capacitors for voltage balance and under or overvoltage If either should occur the appropriate signal is sent to the con trol board to deactivate the input relay machine output will also be disabled NOTE Unshaded areas of Block Logic Diagram are the subject of discussion PRO CUT 55 LINCOLN E 4 E 4 THEORY OF OPERATION O Cc gt 2 5 4 x Return to Section TOC Return to Master TOC LINE INPUT RECTIFIER rod zo Comzzoorm zgz CONTROL AUX TRANSFORMER MAIN TRANSFORMER Each IGBT pair acts as a switch assembly Each assembly feeds a separate oppositely wound primary winding of the main transformer The reverse direction of current flow through the main transformer primaries and the offset timing of the IGBT pairs induce an AC square wave output signal at the secondary of the main transformer The DC current flow through each primary winding is redirected or clamped back to each respective filter capacitor when the IGBTs are turned off This is need ed due to the inductance of the transformer primary winding The primary currents also pass through the current transformer which sends a signal to the control board If the primary currents are not equal the
17. of AD LNMI YWL 7 83404 t OE 54 E Te a lce4 ee gt gt i O i 9 i SYM l gia 300819313 IV LNW d nue 3189N3 GIONS TOS CONS TUS a rera E 91043705 97043705 870 WWININ 51103412 39 d e lt 1044409 01 7YNOIS eer lt eer OL WNOIS INS ELECTRICAL DIAGRAMS is for reference only It may not be accurate for all mach MEI ZI p MEI ZI 815 22 ABORT ji 1 1 92 L nag 1 99 i 10114 10718 x 1 MI AGI poU ASI 0120 T O 9031 Al at 5 20 Al 620 ASI 2 o MAX xnu 120 vct 9 90 E 3 gt 3 JAIO 1074 29 9 1 3 1 1 2 ge z i eod 1 8 iM yet E 5 128 ve Sh Q 9 7 m vr Bea 20 bza sd 29 x 8 p 1 ro SI napag 154111 sigo NEL ARM 6100 EPI m 113 EET zg 18 L CK MERE 1 2 3009193
18. R24 R35 2 5 19400 2210 221 1 4W Eia Lz R28 R112 R115 8116 117 amp 519400 3321 3 32K 174W Ste 1 1 R118 olo ES UN 9 SP m LIT R29 R81 102 3 5 19400 8250 825 1 4W 8 2 3 x3 2 SIS 831 1 519400 1004 174W PI r4 r4 i R40 R73 107 3 519400 7681 7 68K 1 4W 16 R43 R44 R45 136 R137 R170 8 519400 4751 4 75 gt 5 5 LI L l RILI RIE 0 s R47 R49 R80 R89 R183 5 5 19400 1003 OOK 1 4W p ale 5 efm of elg olo als als L8 819 a 3 lg 215185234 zz 8 5 m R48 R67 R70 R87 R101 5 S 19400 4752 47 5 1 4W i s T 9 LT T T R52 R54 R56 3 S19400 1000 00 1 4W c 73 iM EE R58 R76 R99 R 100 4 5 19400 374 3 74K 1 4W a ow ai lm ll a a ae R72 R187 195 3 1819400 1501 1 4W 5 R77 R82 R175 R 177 4 S 19400 130 1 4W gt e B 14 12 19 R78 R113 114 R159 4 519400 121 21K 1 4W RR E RN 879 883 155 R167 4 5 19400 2213 221K 1 4W 1 09 L Z l ee eel 69 Ld cm _ lL zm eeu 69 R97 519400 8252 82 5K 1 4W R98 519400 243 2 4
19. A 8 O O 4 gt c 2 4 Return to Master PRO CUT 55 LINCOLN amp A 2 A 2 INSTALLATION TECHNICAL SPECIFICATIONS PRO CUT 55 INPUT RATINGS Single Phase Input Input Currents Rated Output Amps Voltage and Hertz 208 1 60 230 1 60 460 1 60 Return to Section TOC Return to Master TOC 208 1 60 230 1 60 460 1 60 Three Phase Input Voltage and Hertz 208 3 60 230 3 60 460 3 60 Return to Section TOC Return to Master TOC 208 3 60 230 3 60 460 3 60 IDLE CURRENT AND WATTS 230 1 60 0 42 Amps 98 Watts RATED OUTPUT Duty Cycle Rated Output Amps 50 55 100 40 O Cc gt 2 5 4 x OUTPUT Current Range Open Circuit Voltage Pilot Current 25 55 Amps 335VDC Maximum 18 Amps Q 10096 Duty Cycle Return to Section TOC Return to Master TOC PRO CUT 55 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O Fle Cc gt 0218 5 4 x Return to Section TOC Return to Master TOC A 3 INSTALLATION TECHNICAL SPECIFICATIONS Cont d PRO CUT 55 GAS REQUIREMENTS Required Gas Flow Rate Required Gas Inlet Pressure 70 PSI 360 SCHF 80 to 150 PSI 4 8 Bar 10160 LHR 5 4 Bar to 10 2 Bar 6 CFM RECOMMENDED INPUT WIRE AND FUSE SIZES For all plasma c
20. _ 3327 H 9 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN amp ELECTRIC PROCUT 55 dil ELECTRICAL DIAGRAMS G 8 PC BOARD ASSEMBLY CONTROL G3328 1 ITEM REQ D PART NO DESCRIPTION 022 50 13490 92 3300 50 C2 C8 C10 C13 C14 C17 C20 31 516668 5 C23 C24 C29 C31 C34 C35 C36 C37 C39 C40 C41 C47 C53 C55 C58 C63 C64 C65 C66 C68 C69 C73 C74 C75 _ _______51 490 121 1900 35 _____ 2 ________ 1 6 500 1 10 50 0047 05 2400 0 C7 C9 513490 93 27 35 15 16 32 33 42 516668 11 1 50 C19 C25 C50 13490 25 4 7 35 C21 C26 C28 C30 C54 C57 513490 42 1 0 35 C62 C71 C22 C43 C44 Return to Section TOC Return to Master TOC 516668 9 150 100
21. A 7 A 7 INSTALLATION GAS INPUT CONNECTIONS Supply the Pro Cut 55 with clean compressed air or nitrogen e Supply pressure must be between 80 psi and 150 psi e Flow rate should be approximately 6 0 cfm 170 l min NOTE Oil in the air supply to the Pro Cut 55 can cause severe problems Use only a clean air supply e Connect the gas supply to the Pro Cut 55 s pneumatic nipple at the air filter See Figure A 3 e Compressed gas should be supplied to the fitting connection mounted on the filter at the rear of the machine If necessary this fitting can be removed allowing plumbing access through the 1 4 in 6 4mm NPT input port on the filter body WARNING CYLINDER could explode if damaged Keep cylinder upright and chained to a fixed support FIGURE A 3 COMPRESSED GAS CONNECTION 1 e Keep cylinder away from areas gt PNEUMATIC NIPPLE where it could be damaged 3 AIR FILTER 4 FLEX TUBE TO REGULATOR INSIDE MACHINE Never lift machine with cylinder attached e Never allow the cutting torch to touch the cylinder Keep cylinder away from live elec trical parts Maximum inlet pressure 150 psi NOTE When using nitrogen gas from a cylinder the cylinder must have a pressure regulator e Maximum psi from nitrogen gas cylinder to Pro Cut 55 regulator should never exceed 150 psi e Install a hose between the nitrogen gas cylinder reg ulator and the P
22. FUNCTION PROBLEMS Make sure the Pro Cut 55 is reconnected correctly for the input voltage being applied Be sure to remove input power and wait at least one minute before changing the position of the input voltage range switch If the machine is connected for high input voltage the input Capacitors may need condition ing Section Make sure the torch is connect ed properly to the Pro Cut 55 machine Make sure the air supply is con nected and operating properly Make sure the torch head con sumable parts are in place and in good condition Replace if necessary Make sure the torch consum ables are in place and in good condition Replace if neces sary Make sure the air pressure is set at 70 psi 448 kPa and the flow rate is at 6 CFM Make sure there are no kinks or restrictions for air flow in the torch cable RECOMMENDED COURSE OF ACTION 1 Perform the Board HResistance Test and Capacitor Voltage Test 2 Perform the Rectifier 3 he control 6 1 control board may be faulty Replace The primary power board may be faulty Replace Perform the Auxiliary Trans former Test Perform the Trigger Circuit Perform the Gas Solenoid Perform the Torch Continuity and Solenoid Test board may be faulty Replace The output power board ma be faulty Perform the Output Board Resistance Test Perform the Torch Continuit and
23. PRO CUT 55 LINCOLN Return to Master TOC Return to Master TOC O O 4 gt c 2 4 Return to Master Section C 1 Section C 1 TABLE OF CONTENTS ACCESSORIES iz Lc 5 RR e eem Section C Options ACCESSO navium 2 PRO CUT 55 LINCOLN amp Return to Section TOC Return to Master TOC Return to Section TOC O Fle g gt 018 5 Return to Section TOC Return to Master TOC Return to Master TOC 2 2 ACCESSORIES GENERAL OPTIONS ACCESSORIES The following options accessories are available for your Pro Cut 55 from your local Lincoln Distributor K1600 1 Undercarriage A valet style undercarriage with pull out handle for machine only Provides torch and work cable storage 22147 043 Vortech nozzle with an 043 1 2 mm Orifice 22147 068 Vortech nozzle with an 068 1 7 mm Orifice 22149 Electrode replacement electrodes for cut ting 22150 Shield Cup This shields the torch tip and provides more visibility to the workpiece than the drag cup The shield cup does not prevent the torch tip from touching the workpiece 22151 Drag Cup The drag cup protects the torch by preventing the torch from touching the workpiece K1571 Series PCT 80 T
24. cic i H5 D 3 L30K gt L AUX XFMR 1 VMACHINE DWERVIEJ gt MN i e MACHINE OVERVIEW E tem NIE 1 602 SOME OR ALL DF THESE 108 1 I RESISTORS MAY NOT BE PRESENT 1 1 1 1 1 1 1 i p d POWER SUPPLY l wanga Fog COM i 1 CALIBRATION 1 x i fub 2 43 i i CER pU gt eer 4 maa TIUS 7 1 6 ded Grav d OE utes NES T MEN ac ZZ iE 024 a c75 i t i i 1 i gt i L 1 k ree dise i i i 15 154 554 B Es pig ap qe NOR UEM A pco TERRE n 58 ak 7 059 4 ced n X6 te tl GENERAL INFORMATION LAST ND USED ELECTRICAL SYMBOLS PER E1537 X Y 1 Urez CAPACITORS MFDI B22 58v UNLESS OTHERWISE SPECIFIED es A t CB C85 C58 RESISTORS Ohms 1 44 UNLESS OTHERWISE SPECIFIED LABELS c 5 1307 ae 5 C68 DIODES 1409Y UNLESS GTHERWISE SPECIFIED SUPPLY VOLTAGE NET O lt FILENAME G332 _2C 2 lt SUPPLY SOURCE POINT E COM AAAL A 15v COMMON CONNECTION O 1gak
25. CONTROL i 4 ELECTRODE 364 10 2 6 PSI SWITCH 277A POT DISPLAY 5 6 AIR SOL 4 10 ELEC SOL CW MAX 7 8 ELEC SOL 365 10 WORK 10 5 361 2 4 7 CONTROL J20 Olo 32 8 HUS X 302 gt 4 gt W a 2 gt PRESSURE ee PUR 5 D 361 13 IGBT 1 AIR eo G 303 0 6A 366 SOLENOID 8 ClO 342 SLOWBLOW 54 PRIMARY CO 7 J30 H2 H3 H3 9 9 1 4 24 407 54 5 ts 220 400 cic 5e 9 230V 460VAC OUTPUT v 6 3 53 5 440 202 207 206 460V 202 2 2 oO Sa 3 H4 H5 203 203 401 209 _ 200 230 LEFT SIDE OF MACHINE NOTES 1 FOR MACHINES SUPPLIED WITH INPUT CABLE FOR SINGLE PHASE INPUT CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE COLOR CODE CONNECT BLACK amp WHITE LEADS TO SUPPLY CIRCUIT WRAP RED LEAD WITH TO PROVIDE 600V INSULATION OUTPUT BASE CASE FRONT G GREEN FOR THREE PHASE INPUT CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE PC BOARD R RED O CONNECT BLACK RED amp WHITE LEADS TO SUPPLY CIRCUIT J40 W WHITE E 2 FOR MACHINES NOT SUPPLIED WITH INPUT CABLE U BLUE FOR SINGLE PHASE INPUT GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES PROTECTIVE BONDING CIRCUIT 000000000000000 N BROWN CONNECT TERMINALS U amp W TO SUPPLY CIRCUI
26. D 4 0 gt t gt c O 19 4 Q c oc OE z gt N a oc gt gt 72 2 S E x m c o Q 2 E 599 3 2 E Foe 2 9 0 Seta TE 8 gt o o 5 o lt Hn 0 c o x 98 lt gt A 4 i d NOL 491Se A 0 uunjeH NOL 491Se N 01 uunjeH NOL 0 uunjeH NOL uunjeH DOL uonoes DOL uonoes DOL DOL Section E 1 Section E 1 TABLE OF CONTENTS THEORY OF OPERATION SECTION Theory ot VE vd vx nir ea ara aep Fc dira ark ei Cr ra adul abe y dar a a Section E 9 General ELE E UT E 2 E Input Line Voltage Contactor and Main 4200480 E 2 d Precharge and PROVE E 3 NR EE TIER E 4 OUI GUE Board and TORN NET TR E 5 Control and Display unice oriente he beatum ade wi Ua E 6 PETERE T a E 7 PET
27. TROUBLESHOOTING amp REPAIR DISPLAY BOARD REMOVAL amp REPLACEMENT continued FIGURE F 20 DISPLAY BOARD REMOVAL DISPLAY BOARD CASE FRONT N 5 Locate the display P C board and the one 8 When replacing the display board carefully plug connected to it See Figure 20 connect the plug into the board Make cer tain the plug is secure and the locking tab is 6 Gently remove the display P C board from in place the three mounting pins 9 Align the display board with the three mounting pins and slide the display board CAUTION into place Be sure to follow the recommended static free 10 Carefully reposition the front assembly in methods for handling printed circuit boards place and install the four mounting screws Failure to do so can result in permanent damage previously removed toe GAUPE 11 Inspect clear and secure all leads in prepa ration for the case wraparound reassembly 7 Depress the locking tab and remove the plug 12 Using the 5 16 nut driver install the case connector from the display board wraparound PRO CUT 55 LINCOLN F 57 LINCOLN amp NOTES PRO CUT 55 F 57 NOL 491Se A 0 uunjeH 901 491Se N 01 uunjeH NOL J91Se AN 0 uunjeH NOL uunjeH DOL uonoes uunjeg DOL uonoes uunjeg DOL DOL F 58 F 58 TROUBLESHOOTING amp REPAIR OUTPUT POWER BOARD REMOV
28. Electrical Isolation of Circuits Open very high Torch Consumables Removed Pins 1 amp 9 to all other pins Electrical Isolation of Torch Trigger Circuit Open very high Pins 2 amp 3 to all other pins Electrical Isolation of Torch Solenoid Circuit Open very high 4 any of the resistance checks are not cor 9 rect the torch assembly may be faulty Repair or replace Carefully apply the 12 VDC supply to the electrode solenoid positive to Pin 2 and negative to Pin 3 The electrode solenoid should activate Listen for the solenoid action in the torch handle If the solenoid does not activate it may be faulty Replace Return to Section TOC Return to Master TOC PRO CUT 55 LINCOLN F 31 LINCOLN amp NOTES PRO CUT 55 F 31 NOL 491Se A 0 uunjeH 901 491Se N 01 uunjeH NOL J91Se AN 0 uunjeH NOL uunjeH DOL uonoes uunjeg DOL uonoes uunjeg DOL DOL F 32 F 32 TROUBLESHOOTING amp REPAIR AIR GAS SOLENOID TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this ma
29. Make sure the operating proce dure is correct for the process See the section of this manual Make sure the work clamp is connected tightly to the work piece Make sure the torch consum ables are in place and in good condition Make sure the air supply is not contaminated with oil or exces sive water Make sure the air pressure is set at 70 psi 448 kPa and the flow rate is at 6 CFM Make sure the air hose and Nuisance safety trips screen are not clogged See Safety Status Indicator in the operation section Make sure the correct nozzles are being used for the material thickness See Make sure the output control is set correctly for the process The control The control The control Perform the Torch Continui and Solenoid Test The output board may be faulty Replace board may be faulty Replace Perform Torch Continuity and Solenoid lest The output board may be faulty Replace board may be faulty Replace The torch may be faulty Check or replace board may be faulty See Torch Continuit and Solenoid Test A CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 PRO CUT 55 LINCOLN Return to Sec
30. Moa P X Og 027 038 4n C81 087 078 CONNECTION R R86 THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC CO RUS RIE R28 188 ROA C 16671024878 RG TO R32 AAO RISE ALES EARTH GROUND CONNECTION V fe gt 1 15 NOT BE REPRODUCED DISCLOSED DR USEG WITHOUT THE EXPRESS PERMISSION OFTHE LINCOLN ELECTRIC p l a mu mmn T E P ojo Sen Donn mac 025 NOTES OTHERWISE specietep THE LINCOLN ELECTRIC PRO CUT 55 3125 438 ed 225 QU E 4504 ten Cia SINCE COMPONENTS OR CIRCUITRY ON A PRINTEO CIRCUIT BOARD CHANGE OX S PLACE DECIMALS 15 02 110 31 97 CLEVELAND OHIO U S A sugsecT SCHEMATIC CONTROL c c 00050 E 2 555 4 1 7815 AFFECTING THE INTERCHANGEABILITY OF COMPLETE BOARD THIS DIAGRAM MAY ON ALL ANGLES IS 8 OF DEGREE if SCALE BONE __ ooj 680 n ono NOT SHOW THE EXACT COMPONENTS DR CIRCUITRY OF CONTROLS HAVING A COMMON CODA MATERIAL TOLERANCE ivi TO AGREE je p i amp 6 D t Wos E WITH PUBLISHED STANDARES LL BK 18 15 37
31. RETURN MAIN MENU PRO CUT 55 For use with machine code numbers Below 11000 SVM140 A July 2005 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 thoughtful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READ ING THIS MANUAL AND THE SAFETY PRECAUTIONS CON TAINED THROUGHOUT And most importantly think before you act and be careful Return to Master TOC View Safety Info 5 fl 91 zu e 5 gt SERVICE MANUAL eS m View Safety Info NCOLN Copyright 2005 Lincoln Global Inc e World s Leader in Welding and Cutting Products e 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 Return to Master TOC Return to Master TOC O O 4 gt c 2 4 Return to Master SAFETY PLASMA CUTTING or GOUGING can be hazardous WARNING PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety hig
32. face so it will not topple over HIGH FREQUENCY INTERFERENCE PROTECTION The Pro Cut 55 employs a touch start mechanism for arc initiation This eliminates high frequency emissions from the machine as compared with spark gap and solid state type high frequency generators Keep in mind though that these machines may be used in an environment where other high frequency generating machines are operating By taking the following steps you can minimize high frequency interference Make sure the power supply chassis is connected to a good earth ground The work terminal ground does NOT ground the machine frame Keep the work ground clamp isolated from other work clamps that have high frequency e If the ground clamp cannot be isolated then keep the clamp as far as possible from other work clamp con nections When the machine is enclosed in a metal building several good earth driven electrical grounds around the periphery of the building are recommended Failure to observe these recommended installation procedures may cause improper function of the Pro Cut or possibly even damage the control system or power supply components PRO CUT 55 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC O Fle E 1 gt 3 5 4 cc Return to Section TOC Return to Master TOC Return to Master TOC A 5 A 5 INSTALLATION INPUT CONN
33. 7 100 C45 1 516668 4 2700pF750 C46 C52 2 516668 13 7100 C48 1 S16668 8 330pF 7 100 C56 513490 108 157 100 C59 516668 3 100 C60 513430 126 10187507 C61 513430 15 8720 C72 516668 10 4700pF 750 C76 1 513490 135 0750V D 1 D2 D3 D4 55 06 07 08 09 15 12 199 1 N4004 D14 D20 D23 D25 D26 D27 010 D11 012 013 4 T12705 37 N5822 SCHOTTKY BARRIER DIODE 015 016 017 018 4 T12705 34 4936 r 1 V B D21 T12705 23 N5818 l 6 Y 071 072 2 12702 19 N47428 PRO CUT 50 CONTROL LLLI LL Sa 074 T12702 52 7 EN C52 J 1 518248 4 HEADER Lr 1 fe fel fel le 0 LEE S B N o J2 1 518248 10 HEADER c u 8 7 6 15 73 1 518248 16 HEADER IN Lesa 9 o 2 Yi 74 518248 6 HEADER 4 x18 R173 Di 25 518248 8 HEADER i r Cx X LED2 LED3 3 1136572 RED LED NA Vy 45 11 OT 02 03 3 712704 68 254401 o gt SON V RC ME 96 04 712704280 HEXFET TRANS SS n L 465 T 05 1 T12704 65 2N4403 olo C la 2 id x5 Et R133 FUR RT i Ti3165 i6 1 0 OHM RESISTOR LB x 9 R2 R46 R133 3 S 19400 2671 2 67K 1 4W c c _ Fr Go R3 R30 R32 R33 R34 R36 R37 9 519400 2430 243 174 R38 R39 N Wd e R4 i
34. F 40 F 40 TROUBLESHOOTING amp REPAIR TRIGGER CIRCUIT TEST continued 9 With the torch trigger activated check the voltage at plug J32 pin 3 lead 344 posi tive to plug J32 14 lead 312 nega tive Normal is less than 1 VDC If more than 1 VDC is indicated the power output board may be faulty Release deactivate the torch trigger and remove input power to the Pro Cut 55 10 Perform the Input Filter Capacitor Discharge Procedure 11 Check the continuity of leads 344 and 312 between the output board and the control board See the and 12 If all of the above checks are OK the con trol board may be faulty Replace Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O Fle Cc gt 0218 5 4 x Return to Section TOC Return to Master TOC PRO CUT 55 LINCOLN amp Return to Section TOC Return to Master TOC Return to Section TOC O Fle Cc gt 0218 5 4 x Return to Section TOC Return to Master TOC Return to Master TOC F 41 TROUBLESHOOTING amp REPAIR TRIGGER CIRCUIT TEST continued FIGURE F 10 OUTPUT BOARD TRIGGER CIRCUIT TEST POINTS AND LEDS G3326 PRO CUT 55 OUTPUT LED3 LED5 e LEAD 2 LEAD 4 J32 LEAD 312 LEAD 344 D25 LED4 LED2 PRO CUT 55 OUTPUT BOARD LED DEFINITIONS LED1 Red Thi
35. N4735 DZ2 DZ3 DZ6 DZ7 DZ8 DZ10 T12702 29 1N4744A DZ11 DZ13 DZ14 OCI1 OCI2 15000 22 OPTO ISOLATOR R1 R6 R20 R25 R41 R46 R62 12 519400 10 0 10 1 4W 1 R2 R3 R4 R5 R21 R22 R23 519400 1001 1 4W HER HER R63 R64 R65 R66 R7 R8 R26 R27 R47 R48 R68 T14648 21 2 7 OHM 5W R69 3 100 R50 R51 R83 R86 519400 2673 267K 1 4W 710812 41 LOK 1 2W TRIMMER 3 R29 R30 R31 R32 R71 R72 T14648 12 1500 OHM 5 WATT RESISTOR R73 R74 R33 R38 R58 519400 3321 3 32K 1 4W R36 R52 R89 R90 4 519400 6191 DbisKi 4w R37 R55 R91 R92 4 519400 4502 5K 1 4W 519400 1652 16 5K 1 4W 002 T12705 44 DIODE 1000V 1A Return to Section TOC Return to Master TOC R80 I mm N 97 O Fle E 1 gt 3 5 4 cc TUTTI 919400 R76 R98 19400 4751 4 75K 519400 4752 47 5 1 4W 2 519400 2211 2 21K 1 4W R97 1 0 T12300 79 1 WATT 1 OHM 1 RESISTOR 513000 46 TRANSFORMER 515128 10 VOLTAGE REF 515128 4 LM224 515128 18 QUAD OP AMP NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is pro vided for reference only Lincoln E
36. 1 d 112702 542 1N4733A S2035 1 6 HEADER OCIJ DELZ S 15000 22 ISOLATOR 01 T12704 75 056 02 03 04 05 T12704 73 IC PKG MOSFET SS R 1 R6 R20 R25 R41 R46 R62 S 19400 10RO 10 1 4W R67 R79 R80 R8 1 R82 R2 R4 R5 R18 R2 1 R22 S 19400 1001 1 1 4W R23 R24 R42 R43 R44 R45 R60 R63 R64 R65 R66 R73 R99 R 100 R7 R8 R26 R27 R47 R48 R68 8 T14648 21 2 7 OW R69 10 R11 R12 524376 3 100 10 R13 R14 R15 R16 R34 R35 10 S 19400 1503 150K 1 4W R17 R19 R29 R30 R31 3 S 19400 2213 221K 1 4W R49 R6 1 R74 R28 1 108 12 41 10K 1 2W TRIMMER R32 R71 R98 3 19400 2212 22 IK 1 4W R33 R38 2 5 19400 3321 3 32K 1 4 R36 R52 R89 R90 4 19400 8181 6 19K 1 4W 837 85 833 1 1 1 SS 19400 7681 7 68K 1 4W R39 R63 R57 870 885 7 5 19400 1002 10K 1744 19400 1372 13 7 1 44 1 S 19400 2941 2 94K 1 4W 1 S 19400 1000 100 1 4W 562 1 4W 1 S 19400 2801 2 8K 1 4W 1 519400 4751 4 75K 1 519400 1822 18 2K 1 4W 2 519400 3323 332K 1 4W 1 519400 1652 16 1 4W 2 S 19400 1502 ISK 1 4W 1 19400 4752 47 1 4 I i 2 21K 1 4W 1 T12300 79 1 WATT 1 OHM 1 RESISTOR 102 103 104 R105 12 T14648 19 1K 5W 107 R108 R109 R 110 ui R112 1 619400 1821 1 82K 1 4W R114 R115 116 117 4 S 19400 1004 IM 1 4W T1 1 S 13000 46 TRANSFORMER X1 1 815128 10 431 VOLTAGE REF X2 X3 2 S
37. 15 128 4 LM224 OP AMP NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the LINCOLN machine G 13 PROCUT 55 Return to Master TOC Return to Master TOC O O 4 gt c 2 4 Return to Master SVM ERROR REPORTING FORM We need to know if there are errors in our manuals We also value any suggestions as to additional tests or procedures that would make this SVM a better tool for you If you discover new or different Problems or Symptoms that are not covered in the three col umn troubleshooting chart please share this information with us Please include the machine s code number and how the problem was resolved Thank You Technical Services Group Lincoln Electric Co 22801 ST Clair Ave Cleveland Ohio 44117 1199 FAX 216 481 2309 SVM Number Page Number if necessary Your Company Your Name Please give detailed description below SD287 01 99 LINCOLN
38. 6 Carefully check for the presence of the fol 3 Locate the auxiliary transformer just behind owing e the input line switch on the lower right side of appropriate leads al pilds 971 andes Figure F 8 and Table F 6 4 Locate and disconnect plugs J21 and J22 from the wiring harness Cut any necessary cable ties See Figure F 8 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC PRO CUT 55 LINCOLN amp Return to Section TOC Return to Master TOC Return to Section TOC O Fle Cc gt 0218 5 4 x Return to Section TOC Return to Master TOC Return to Master TOC F 36 TROUBLESHOOTING amp REPAIR T2 AUXILIARY TRANSFORMER TEST continued TABLE F 6 J21 AND J22 6 Pin VOLTAGES TEST POINT EXPECTED VOLTAGE H1 1 22 200 208VAC H1 1 22 380 415VAC H1 1 22 440 460VAC Brown 8 21 12VAC Red 2J 21 24VAC Blue 9 21 18VAC Blue 4 21 18VAC J21 AND 422 8 Pin VOLTAGES TEST POINT EXPECTED VOLTAGE H1 1J 22 200 208VAC H1 1J 22 380 415VAC H1 1 22 440 460VAC H1 1 22 560 600VAC Brown 8 21 12VAC Red 2 21 24VAC Blue 9 21 18VAC Blue 4J 21 White 5 21 18VAC 7 the correct test voltages are present the 10 When finished with the test replace plugs auxiliary transformer is good 21 and 22 and the case wraparound 8 If any of the voltages a
39. 818400 30R1 30 1 174W i 1 2 o 5 5 m Je 819400 6190 619 174W I LH 2 NU NM 5 22 Y R6 1 519400 8251 8 25K 174W I E Mas elsl elg x12 R7 R190 191 R193 R194 5 5 19400 3921 3 92K 174W gt 51 5 5 5 R8 1 519400 2001 2 0K 174W NO T TOT V R9 R88 R103 3 519400 1001 174W l lt 10 R42 R95 R96 4 519400 5110 511 174W cS Ras 021 SRE AN RILRI2 13 14 4 519400 3320 332 174W E P AES ca Tae Eee elef R17 R26 R27 R6 1 R62 R63 32 519400 1002 174W i R24 E R68 R69 R8 1 284 R93 R94 E x1 R104 R106 108 134 R138 866 139 152 R 153 154 R156 1 Lers 3 71 158 160 164 165 R166 m f l R178 R179 R180 R181 R182 R18 1 24073 1 10K 1 2W TRIMMER N se Sl WS Les 3 i R19 R53 855 R57 85 149 7 519400 5111 5 11K 1 4W oT mas H R157 T 18144 R20 R22 110 111 R 124 16 519400 10RO 10 1 4W 5 R125 126 127 R128 R142 eeu RR Rs LI LL R143 R144 145 8146 R147 CORGO A E R196 O10 xs Esse 8118 4 R21 R23 2 S 19400 1822 18 20 1 4W 57955 gt R19
40. BOARD BLANK 2 1 19365 15 RIGHT ANGLE HEADER 3 3 oz E2861 SEALANT ME INDUCTANCE HENRYS 3 PLACES 4 00 1 65 04 8 3 MANUFACTURED AS O o gt a 9 LED9 LED6 LED5 LED3 522222 11 5 ii ai t 4 L10721 1A0 APT li EE o olg c LED8 LED7 1 04 LED2 IDENTIFICATION CODE 5 2 LED TIME 1 20 49 D J R14 671 C5 LL ERREF olo MAKE PER E1911 TERLER ENCAPSULATE WITH E1844 255555 Siz TEST PER E3733 D NS J40 9 L10721 1 i 0 0 4 39 4507 04 N C N C NOTES N A DO NOT COAT O N B DO NOT COAT VIEWING LENS WITH E ENCAPSULATION MATERIAL rir N C COAT WITH ITEM 3 COMPONENT SIDE AFTER ENCAPSULATION 5 D m N D HEIGHT OF RTV AND COMPONENTS NOT TO EXCEED 36 adu k 5 COAT WITH ITEM 3 oa AND SOLDER CONNECTIONS ON gt NON COMPONENT SIDE OF BOARD PRIOR TO ENCAPSUATION 212 avo a NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise
41. C45 16668 4 P700pF 50 C46 C52 16668 13 10 100 s16668 8 0 100 C56 13490 108 15 100 516668 3 __ 100 100 513490 126 018 50 14 13490 19 1 8 20 C72 16668 10 4700pF 50 1 69 6 Y D1 D2 D3 D4 D5 D6 D7 D8 D9 16 T12199 1 1N4004 1 50 CONTROL G3328 M D14 D20 D22 D23 D25 D26 D27 1 o 3 D10 D11 D12 D13 4 T12704 37 1 5822 SCHO TKY BARRIER DIODE a a 52 1 E 2 z 2 2 z 48 3 D15 D16 D17 D18 D21 T12705 34 1N4936 t 8 M ear pata TTTT Qi i 021 022 2702 19 1 4742 o xe 5 HEADER a ISIS 2 Po _____18248 __ ooo d _ o 29 18248 10 HEADER cla f EE 38 Cac 518248 16 HEADER 518248 6 t x5 R61 518248 8 HEADER LED1 LED2 LED3 _____ 3 ____ gt 1 n LED1 LED2 LED3 3 713654 2 RED LED Y h 1 01 02 03 12704 68 2N4401 on i T12704 80 HEXFET TRANS SS I Gn 112704 69 HEXFET TRANS 55 1 13165 16 1 0 OHM sw RESISTOR I R2 R46 R132 S19400 2671 2 67K 1 4W in o X12 c 2 R3 R30 R32 R33 R34 R36 R37 519400 2430 243 1 4w c E R38 R39 gt LED1 p 19400 30R1 3
42. Either the duty cycle has been exceeded the fans are not functioning or the louvers are blocked ly with the Thermal LED lit the display board may be faulty Replace Return to Section TOC Return to Master TOC O Fle g gt 018 5 CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 Return to Section TOC Return to Master TOC PRO CUT 55 LINCOLN amp F 10 ooueuuojed ees 4 1 no soob 1910 44 eoueuuoped 196611 0 paJnoes 1 j Jeuonounj si uieis S eins Spuooes Ind pue 1404 seoq 49091 0 1ndino 25 pue 1014 51 4591 05 pue 4010 BY 1 10 ejquuessesiq aq 5 sajqewnsuoy ayouy 5 21816 1019 seop Spuooes
43. Return to Master TOC E 8 E 8 THEORY OF OPERATION INSULATED GATE BIPOLAR TRANSISTOR IGBT OPERATION An IGBT is a type of transistor IGBTs are semicon ductors well suited for high frequency switching and high current applications Drawing A shows an IGBT in a passive mode There is no gate signal zero volts relative to the source and therefore no current flow The drain terminal of the IGBT may be connected to a voltage supply but since there is no conduction the circuit will not supply cur rent to components connected to the source The cir cuit is turned off like a light switch in the OFF position Drawing B shows the IGBT in an active mode When the gate signal a positive DC voltage relative to the source is applied to the gate terminal of the IGBT it is capable of conducting current A voltage supply connected to the drain terminal will allow the IGBT to conduct and supply current to circuit components coupled to the source Current will flow through the conducting IGBT to downstream components as long as the positive gate signal is present This is similar to turning ON a light switch FIGURE E 7 IGBT OPERATION BODY REGION BUFFER LAYER lt INJECTING LAYER DRAIN A PASSIVE lt DRAIN DRIFT REGION POSITIVE VOLTAGE go GATE BODY REGION lt DRAIN DRIFT REGION lt BUFFER LAYER INJECTING LAYER B ACTIVE PRO CUT 55 LINCOLN Return to Section T
44. S 7 7 Insulated Gate Bipolar Transistor IGBT Operation esee E 8 Pulse Width Modulation oia E 9 O O 1 gt gt c 2 FIGURE E 1 PRO CUT 55 BLOCK LOGIC DIAGRAM WORK NOZZLE ELECTRODE POWER BOARD MAIN TORCH TRANSFORMER OUTPUT BOARD TN CONNECTOR ke INPUT LINE SWITCH 0 gt PILOT TRANSISTOR 9 TRIGGER amp SAFETY 5 W AR OLENOID AIR B PRESSURE SWITCH t ELECTRODE amp TRANSFER 9 SIGNAL PILOT ENABLE ELECTRODE SOLENOID ENABLE AIR SOLENOID ENABLE S Y FAN MOTORS ADV AUX TRANSFORMER Return to Master TOC PRO CUT 55 LINCOLN amp E 2 E 2 THEORY OF OPERATION FIGURE E 2 INPUT LINE VOLTAGE Return to Section TOC Return to Master TOC O10 O Cc gt 2 5 4 x Return to Section TOC Return to Master TOC POWER BOARD INPUT INPUT SWITCH RECTIFIER rod zo Comzzoorm zgz CONTROL AUX ARY TRANSFORMER GENERAL DESCRIPTION The Pro Cut 55 is a constant current continuous con trol plasma cutting power source The inverter based power supply design is controlled by a micropr
45. Test F 18 Output Power Board Resistance F 24 Torch Continuity and Solenoid F 28 GES Solenoid TST MERE F 32 T2 Auxiliary Transformer 34 F 34 Taggar CIC UNE MSE sped C P F 38 Low Voltage Circuit F 44 Replacement Procedures Control Board Removal and F 50 Display Board Removal and F 54 Output Power Board Removal and F 58 Primary Power Board and Filter Capacitor Removal and Replacement F 62 Input Rectifier Bridge Removal and F 66 Retest after Repair haa F 69 PRO CUT 55 LINCOLN 5 Section F 1 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O Fle g gt 018 5 Return to Section TOC Return to Master TOC F 2 TROUBLESHOOTING amp REPAIR HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and repair should be performed by only Lincoln Electric Factory Trained Personnel Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your facto
46. abnormal check the continuity zero or very low resistance of leads 366 and 361 between the solenoid and plug J31 AIR SOLENOID See the Wiring Diagram If the leads are good the solenoid coil may be faulty Carefully apply the 12 VDC supply to the solenoid leads at plug J31 positive to J31 pin 6 lead 366 and negative to J31 pin 5 lead 361 With proper air pressure applied the sole noid should activate and air should flow If the solenoid activates but air does not flow check for a restriction in the air line Install plug J31 back into the output power board FIGURE F 7 PLUG J31 LOCATION R5 Test Point 93326 PRO CUT 55 OUTPIUT J32 PRO CUT 55 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O g gt 018 5 oO Return to Section TOC Return to Master TOC F 34 TROUBLESHOOTING amp REPAIR T2 AUXILIARY TRANSFORMER TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock pleas
47. control board compensates by adjusting the IGBT gate signals DISPLAY BOARD O10 FIGURE E 4 MAIN TRANSFORMER c oic gt WORK 2 8 Y NOZZLE 5 ELECTRODE POWER BOARD ac MAIN TORCH TRANSFORMER OUTPUT BOARD CONNECTOR poto Vg TRIGGER amp SAFETY AIR OLENOID c AIR i PRESSURE 51 SWITCH i S gt ELECTRODE amp TRANSFER CURRENT FEEDBACK 9 PILOT ENABLE c CONTROL BOARD ELECTRODE SOLENOID ENABLE 5 AIR SOLENOID ENABLE E R E F A R t Y OUTPUT The firing of both IGBT pairs occurs during halves of the 50 microsecond intervals creating a constant 20KHZ output The secondary portion of the main transformer is made up of two separate windings One secondary winding supplies the electrode to work voltage This is the high current winding which is capable of supplying maximum output current during the cutting process The other secondary winding supplies the electrode to nozzle voltage for the pilot arc current The con ductor in this winding is smaller since the pilot current is considerably less than the cutting current While one winding is conducting the other winding is at a lim ited voltage and aids in the arc transfer to and from the workpiece PRO CUT 55 LINCOLN THEORY OF OPERATION Return to Section TOC Return to Master TO
48. from the bly See Figure F 5 machine PRO CUT 55 LINCOLN amp Return to Section TOC Return to Master TOC Return to Section TOC O Fle Cc gt 0218 5 4 x Return to Master TOC F 30 F 30 TROUBLESHOOTING amp REPAIR TORCH CONTINUITY AND SOLENOID TEST continued TABLE F 5 TORCH ASSEMBLY RESISTANCES TEST CIRCUIT S BEING EXPECTED TEST POINTS TESTED RESISTANCE CONDITIONS Pin 7 to Pin 8 Parallel pilot arc leads 1 5 ohms maximum None Pin 7 to Torch Nozzle One pilot arc lead to nozzle 1 0 ohm maximum Torch consumables in place Pin 8 to Torch Nozzle One pilot arc lead to nozzle 1 0 ohm maximum Torch consumables in place Pin 1 to Pin 9 Torch trigger circuit 100K ohms minimum Torch trigger NOT pulled not activated Pin 1 to Pin 9 Torch trigger circuit 1 0 ohm maximum Torch trigger pulled activated Pin 2 to Pin 3 Electrode Solenoid 45 to 55 ohms None Pin 7 to Torch Electrode at machine end of torch Pilot and Electrode circuit 1 0 ohm maximum Torch consumables in place Pin 8 to Torch Electrode at machine end of torch Pilot and Electrode circuit 1 0 ohm maximum Torch consumables in place Pin 7 To Pin 1 Pin 2 Pin 3 Pin 9 Electrical Isolation of Circuits Open very high Torch Consumables Removed Pin 8 To Pin 1 Pin 2 Pin 3 Pin 9
49. input power cord as it passes through the left rear access hole The cord connector is designed for a cord diameter of 40 1 03 in 10 2 26 2mm if it becomes necessary to install a different input cord See Figure A 1 For three phase connection Replace the input power cord with 10 AWG 4 lead cable Connect the leads of the cable to a fused power panel Make sure the green lead is connected to the panel and the panel is connected to a good earth ground Install in accordance with all local and national electric codes INPUT WIRE AND FUSE SIZE Fuse the input circuit with the super lag fuses or dela type circuit breakers recommended the Technical Specifications page Choose an input and grounding wire size according to local or national codes also see the Technical Specifications page Using fuses or circuit breakers smaller than recommended may result in nuisance shut offs from inrush currents even if you are not cutting at high currents PRO CUT 55 LINCOLN amp Return to Section TOC Return to Section TOC Return to Master TOC O O 0 4 c 2 4 Return to Section Return to Master TOC Return to Master TOC O O 4 gt c 2 4 INSTALLATION RECONNECT PROCEDURE FIGURE A 2 RECONNECTION DIAGRAM When received directly from the factory the machines are internally connected for 230 VAC R
50. lead 4 The torch trigger must be pulled and all input power removed from the machine If conti nuity less than one ohm is not read check the leads from plug J31 to the torch cable receptacle Perform the Torch Continuity and Solenoid Test If less than one ohm is read only when the torch trigger is pulled proceed to the next step Also see Output Board LED Definitions and related figures Apply the correct input power to the Pro Cut 55 Carefully check for approximately 17 VDC from plug J31 pin 1 lead 4 positive to plug J31 pin 2 lead 2 negative See If the correct voltage is not pre sent perform the Low Voltage Circuit Test Also see Output Board LED Definitions and related figures CONTROL BOARD P R S S R If the correct voltage is present in Step 6 carefully check for the presence of approxi mately 15 VDC from plug 432 3 lead 344 positive to plug J32 pin 14 312 negative See Figure F 10 Also see and related figures If the correct voltage is not present perform the Low Voltage Circuit If the correct voltage is present in the above test carefully pull the torch trigger A WARNING PILOT ARC CUTTING ARC AND HIGH VOLT gt TORCH HEAD Perform this test with the air input removed to avoid a pilot arc at the torch AGE MAY BE PRESENT AT THE Return to Section TOC Return to Master TOC PRO CUT 55 LINCOLN amp
51. off The pressure gauge may show an increase in pressure after the air turns off but this is normal Do NOT reset the pressure while the air is NOT flowing e When ready to cut place the torch near the work make certain all safety precautions have been taken and pull the trigger The air will flow for a preflow time of 2 seconds and the pilot arc will start This is true unless the machine is in postflow then the preflow time is skipped and the pilot arc will start immediately The pilot arc will run for 3 seconds and shut off unless the arc is brought in contact with the work and the arc is transferred Avoid excessive pilot arc time by transferring the arc to the workpiece quickly to improve parts life When the arc is brought within 1 4 in 6 4mm from the workpiece the arc will transfer the cur rent will ramp up to the setting on the control panel and the cut can last indefinitely or until the duty cycle of the Pro Cut is exceeded Do not touch the nozzle to the work when cutting Damage to the consumables may result e Pierce the workpiece by slowly lowering the torch onto the metal at a 30 angle away from the opera tor This will blow the dross away from the torch tip Slowly rotate the torch to vertical position as the arc becomes deeper TORCH AT 30 ANGLE TO PIERCE ROTATE TO 90 ANGLE TO CUT 1907 VERTICAL ANGLE FORICUTTING e Hold the nozzle standoff 1 8 in 8 2mm to 3 16 in 4 7mm
52. procedures referred to in the Troubleshooting Guide are described in detail at the end of this chapter Refer to the Troubleshooting and Repair Table of Contents to locate each specific Test Procedure All of the referred to test points Components terminal strips etc can be found on the referenced elec trical wiring diagrams and schematics Refer to the Electrical Diagrams Section Table of Contents to locate the appropriate diagram A CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 PRO CUT 55 LINCOLN amp F 2 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O o Cc gt 0218 5 4 oO x Return to Section TOC Return to Master TOC TROUBLESHOOTING amp REPAIR PC BOARD TROUBLESHOOTING PROCEDURES WARNING ELECTRIC SHOCK can kill Have an electrician install and service this equipment Turn the input power OFF at the fuse box before working on equipment Do not touch electrically hot parts CAUTION Sometimes machine failures appear to be due to board failures These problems can sometimes be traced to poor electrical connections To avoid prob lems when troubleshooting and replacing PC boar
53. the machine is self draining and will not have to be emptied Check the filter element every several months to see if it is clogged weekly in very dirty environ ments Replace if necessary by first removing the two screws that attach the filter cage to the back panel assembly then slide the cage away from the back of the machine and remove Next twist the Clear filter bowl until it comes off be careful not to lose the o ring seated at the top of the bowl threads Unscrew the filter element and replace with new element Assemble parts in reverse order as described above Inspect the cable periodically for any slits or punc ture marks in the cable jacket Replace if neces sary Check to make sure that nothing is crushing the cable and blocking the flow of air through the air tube inside Also check for kinks in the cable periodically and relieve any so as not to restrict the flow of air to the torch PERIODIC MAINTENANCE WARNING ELECTRIC SHOCK can kill 0 e Turn off machine at the disconnect switch on the front of the machine before tightening cleaning or replacing consumables Change consumables as required 1 Thermal Protection Two thermostats protect the machine from excessive operating temperatures Excessive temperatures may be caused by a lack of cooling air or by operating the machine beyond the duty cycle and output rating If excessive operating temperatures should occur the yellow ther
54. 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 LINCOLN machine ELECTRIC PROCUT 55 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O O 0 c 2 4 Return to Section TOC Return to Master TOC O O gt c 2 6 SCHEMATIC DISPLAY PC BOARD 02681 102 100 al Jig 23 2 4401 AT SA 60 C1 2700p S 50 15V COM AIR LOW SIGNAL 13 C2 2700p THERMAL SIGNAL 9 C3 2700 5 V SAFETY lt SIGNAL 4 2700 BBV 15 LINCOLN ELECTRICAL DIAGRAMS HLMP 2655 HLMP 2458 2358 NOTES SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF COMPLETE BOARD THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING COMMON CODE NUMBER THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC CO AND 5 NOT TO BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OFTHE LINCOLN ELECTRIC CO UNLESS OTHERWISE SPECIFIED TOLERANCE ON HOLES SIZES PER 2056 ON 2 PLACE DECIMALS IS 02 ON 3 PLACE DECIMALS 15 002 Ch ga Sht No NEUE ME
55. to indicate this activity The electrode solenoid will then be energized for the duration of post flow The LED should be on LED6 Green transistor Indicates gate drive for pilot PRO CUT 55 LINCOLN amp F 42 F 42 TROUBLESHOOTING amp REPAIR TRIGGER CIRCUIT TEST continued FIGURE F 11 CONTROL BOARD LEDs PRO CUT 55 CONTROL G3328 Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC CONTROL BOARD LED DEFINITIONS LED1 Red This light indicates that 18 VAC is being supplied to the control board from the auxiliary transformer It also shows that the 18 VAC is being rectified and should be regulated to 15 VDC This 15 VDC supply is used to power the circuitry on the control board LED2 Red This light indicates that the 5 5 VDC is present This voltage is derived from the 15 VDC supply The 5 5 VDC supply is used to power the circuitry on the control board LEDS Red This light indicates that 18 VAC is being supplied to the control board from the auxiliary transformer It also shows that the 18 VAC is being rectified and should be regulated to 15 VDC This 15 VDC supply is used to power the circuitry on the control board O Fle Cc gt 0218 5 4 x Return to Section TOC Return to Master TOC PRO CUT 55 LINCOLN amp F 43 LINCOLN amp NOTES PRO CUT 55 F 43 NOL 491Se A 0 u
56. to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION The procedure will help the technician determine if there is a problem or fault in the inter nal trigger circuit Return to Section TOC Return to Master TOC MATERIALS NEEDED Ohmmeter voltmeter multimeter 5 16 Nut driver Simplified Trigger Circuit Diagram O Fle g gt 018 5 Return to Section TOC Return to Master TOC PRO CUT 55 LINCOLN amp Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O Fle C Ix gt 0218 5 4 cc 39 TRIGGER SWITCH IN TORCH HANDLE F 39 TROUBLESHOOTING amp REPAIR TRIGGER CIRCUIT TEST continued FIGURE F 9 SIMPLIFIED TRIGGER CIRCUIT DIAGRAM Later Versions OUTPUT BOARD TORCH RECEPTACLE PROCEDURE 1 2 Remove input power to the Pro Cut 55 machine Perform the Input Filter Capacitor Discharge Procedure detailed earlier in this section Locate the torch cable receptacle and leads 2 and 4 See Figure E9 the Simplified Trigger Circuit Diagram These leads are best accessed at plug J31 on the output board SeelFigure F 10 Using the ohmmeter check for continuity less than one ohm from lead 2 to
57. 0 11 4W Tel 519400 6190 619 1 4w pee 1 15 2818 x 2 z zzi 2 519400 8251 8 25K 1 4W LEDS us rto E 519400 3921 3 92k 1 4W 30 x ile m 519400 2001 2 0K 1 4W S O T 2 1 R9 R88 R103 19400 1001 1 4W R35 DZ2 71 R10 R42 R95 R96 4 51940425110 00002 podes ane e SL R11 R12 R13 R14 4 51940423320 _____ R S S S R18 4 R17 R26 R27 R49 R51 R59 35 19400 1002 10k 1 4w i ea ae hs CIIM R51 m R26 R27 R49 R51 j pL 1 a a TILE R61 R62 R63 R68 R69 R81 43 R84 R93 R94 R104 R106 R108 gt lt R166 I R134 R138 R139 R152 f rhs R153 R154 R156 R158 R160 T sg ue a ipium R167 2 g z z z Z 5 3 R164 R165 R166 R178 c 71 2 Rig C 1650 R179 R180 R181 R182 DZ1 5 LI TE 3 HE 7 R18 24073 1 10K 1 2W TRIMMER V L d IE Q4 o R19 R47 R53 R55 R57 R85 S19400 5111 5 11K 1 4W 5 5 o ao a a e jalgia ws 2 le S S S e S ael R149 R157 9 o Zu 2 zilo al E JU ZO Z R20 R22 R110 R111 R12
58. 00 ohms Less than 100 ohms Less than 100 ohms Less than 100 ohms Less than 100 ohms Less than 100 ohms 6 5 Less than 100 ohms EE gt Greater than 1000 ohms 018 IB O Greater than 1000 ohms Greater than 1000 ohms 6 If the input rectifier does not meet the accept 7 f the input rectifier is good be sure to recon able readings outlined in Table F 1 the com nect leads 207 207 and 209 to the cor ponent may be faulty Replace rect terminals and torque to 31 in lbs Apply a coating of Essex D 4 8 insulating com NOTE Before replacing the input rectifier D1 check the input power switch S1 and perform the 8 If the input rectifier is faulty see the Input Also check for leaky or faulty filter capacitors procedure See the Wiring Diagram and pound O C Ix gt 0218 5 4 cc Return to Section TOC Return to Master TOC PRO CUT 55 LINCOLN F 17 LINCOLN amp NOTES PRO CUT 55 F 17 NOL 491Se A 0 uunjeH 901 491Se N 01 uunjeH NOL J91Se AN 0 uunjeH NOL uunjeH DOL uonoes uunjeg DOL uonoes uunjeg DOL DOL Return to Section TOC Return to Master TOC Return to Section TOC O Fle g gt 018 5 Return to Section TOC Return to Master TOC Ret
59. 1 This will prevent output TABLE F 3 CAPACITOR VOLTAGES EXPECTED VOLTS DC AT CAPACITOR INPUT APPLIED TERMINALS 460VAC 325VDC 440VAC 311VDC 415VAC 293VDC 380VAC 269VDC Return to Section TOC Return to Master TOC NOTE If Capacitor C1 is found to be defective both Capacitors C1 and C2 must be replaced at the same time The capacitors must be replaced in matched sets O Fle Cc gt 0218 5 4 x Return to Section TOC Return to Master TOC PRO CUT 55 LINCOLN F 23 LINCOLN amp NOTES PRO CUT 55 F 23 NOL 491Se A 0 uunjeH 901 491Se A 0 uunjeH NOL J91Se AN 0 uunjeH NOL uunjeH DOL uonoes DOL uonoes uunjeg DOL DOL F 24 F 24 TROUBLESHOOTING amp REPAIR OUTPUT POWER BOARD RESISTANCE TEST A WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manu al 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 test repairs safely contact the Lincoln Electric Servic
60. 2 205 206 203 Return to Section TOC Return to Master TOC CAPACITOR C1 TERMINALS TEST PROCEDURE 1 Remove main input power to the Pro Cut 4 Carefully remove the main transformer pri 55 mary leads 201 204 205 and 208 2 Perform the Input Filter Capacitor Tomis POWE DOAN Discharge Procedure detailed earlier in 5 Use the analog ohmmeter to perform the this section test outlined in Table F 2 3 Locate the primary power board and asso ciated lead locations See Figure O Fle Cc Ix gt 018 5 4 t cc Return to Section TOC Return to Master TOC PRO CUT 55 LINCOLN amp Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 O C Ix gt 0218 5 4 cc Return to Section TOC Return to Master TOC F 20 6 F 20 TROUBLESHOOTING amp REPAIR PRIMARY POWER BOARD RESISTANCE TEST AND CAPACITOR VOLTAGE TEST continued If the power board does not meet the acceptable readings outlined in Table F2 the board is faulty Replace See Power Board Removal Replacement Procedure NOTE Complete power board and filter capacitor replacement is recom mended TABLE F 2 PRIMARY POWER BOARD RESISTANCE TEST POINTS TEST POINT TERMINALS ANALOG METER X10 RANGE 7 Greater than 1000 ohms Less than 100 ohms Greater than 1000 ohms Less t
61. 208 FH 384 OVERVOLTAGE gt PROTECTION FE 85 Y TE 5 I aoiS9 Jig RECONNECT FIS MISCONNECTION E NE T es 2 MEE PROTECTION EH FREU RECONNECT 5 8 p E CONTROL GATE 22 SiS BOARD guy 59 4 5 o PWM DRIVE 55 212 290 5 lt PRIMARY 325VDC FILTER NOMINAL CAPACITOR TRANSFORMER olo PRIMARY O o Fc 5 i E gt gt T o 2074 1w EGATIVE NOTE 202 203 206 amp 207 BOLT ON WITH FILTER CAPS 4 5 5 lt oO ojo NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN PROCUT 55 olo PC BOARD ASSEMBLY DISPLAY o E ITEM QTY PART No IDENT
62. 3 834 53718 S310H 5551 956 ZYH IS Y 502 91412373 N OONIT JHHO NOISSIMNH3d SS3HdX3 INOHLIM YO C3SOTOSIO 30n004d34 38 LON SI ONY ME NOILJ3NNDJ 220209222 5 esuajejea peenu 02 21415379 NOILYWYOJNI SNIVINOD 13348 SHL fzer 09908 YILINI 945914 SS SIGAN uo wawa xs NO1123NNO2 3002 NOWNOD V 5701909 40 SINSNOdAOO 129 3 MOHS LON __ 5 We 222817 AWN 3113 WHOUIG SIHL OMNOH 3137402 9 30 ALITIBVSONVHOHSINI JHL 941123339 LACHLIN 0900 ANIOd 308105 A dns AV GUYON 110313 Q3INIHd Y NO AULINOYID SINSNUdAUJ AJNIS VN 2221 13N 30V170A 7846 Y 0031419345 3SIMM3HIO 55914 630010 5310 ver aan rix 931319345 ASIMYJHLO 5531 1 Mp I 540151939 0314IJ3dS JSIMYJHLO 959791 ABS ZZ I OAN 580124495 1 20 2 3 8 0 S d 93 0351704 1591 46613 Yad 5108445 1214123 3 NOTLYWHOANT 1U83N32 xn lu 330 4309141 Madd 1 OALHOHS n eee wen 2 Bid Wes abt I
63. 3K 1 4W T R109 S 19400 681 6 81K 1 4W R120 RI21 R122 R123 4 519400 2687 26 7 1 4W R129 5 19400 562 62 1 4W 8130 19400 22 12 22 1K 1741 R131 5 19400 6812 68 IK 1 4W R132 16296 5 TRIMMER R135 R184 2 519400 1502 15 1 4W R140 R141 2 S 19400 2670 267 1 4W R173 T10812 39 1 2W TRIMMER R174 S 19400 5622 56 2 174W R176 S 19400 4750 475 1740 R188 5 19400 3922 39 2K 1 4W R189 R192 2 T 108 12 68 1720 TRIMMER 2 2 13640 153 X 515128 16 C LT1014 LINEAR INTEGRATED CIRCUIT X2 515128 18 330748 QUAD HI GH PERF 15128 4 LM224 0P X4 X6 2 515128 OP27GZ PRECISION X5 524085 3 ROM ASBLY 59 X7 S 18647 LM350 VOLT REG WI TH H S ASSEMBLY c X8 1 518395 13 C 7805 VOLTAGE REGULATOR ASBLY OjO 515128 12 7905 VOLTAGE REGULATOR to X10 X16 2 515018 18 C TCF6000 ARRAY CLAMPING HEX OIG X11 M15 102 3 C S8054HN CMOS UNDERVOT SENSING 9 X12 M15458 2 3846 CONTROLLER 55 o gt X13 x14 2 5150 18 19 C DRIVER FET 6A X15 M15 105 8 AD739 CMOS CONV D A SERIAL 10 55 9 2 X18 M13552 2 C LM2907 CONVERTER F V 1 516665 5 8 0 MHZ 5 5 amp c NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board le
64. 4 519400 1503 150 1 4W 16 SK 1 4W 50 R51 R52 53 4 T14650 1 1500 OHMS 15 RESISTOR T 13640 20 480V 180J MOV T 13640 9 T 13640 15 S 15018 19 DRI VER FET NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the LINCOLN ine LINCOLN 9 meee PROCUT 55 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC gt gt we gt i cc 13326 1 O Fle E gt 3 5 4 cc Return to Section TOC Return to Master TOC G 11 ELECTRICAL DIAGRAMS G 11 PC BOARD ASSEMBLY OUTPUT G3326 2 WEM PARTNO IDENHFCATION D 1 D2 D3 D4 D5 D6 D7 D8 D9 22 12 199 1 134004 010 011 013 014 015 016 026 go GREEN LEDS puo TU 19400 3320 __ 2 R13 R27 3 19400 22 13 221K 1 4W R26
65. 4 R125 16 19400 10R0 10 1 4W 4 2 R126 R127 R128 R142 R143 elol UIl R144 R145 R146 R147 R901 Es E E R111 R21 R23 19400 1822 18 2K 1 4W e 020 j 5 5 lof R110 R24 R35 19400 2210 221 1 4w z C S 18 22 aleaz xz zz 2182 ME c u m e C6 1 R28 R112 R115 R116 R117 19400 3321 3 32 1 4 5 5 1 aa rr 1 e x UE we dw Ww 19 l s mt 1 w uv le l f R29 R91 R102 19400 8250 825 1 4W j 3 J3 J2 l J5 519400 1004 1 1 4W 5 5 5 5 5 R40 R73 R107 519400 7681 7 68K 1 4W 2 9 ionis R171 R172 P ee R48 R67 R70 RB7 R101 519400 4752 47 5K 1 4W R52 R54 R56 19400 1000 100 1 4W R58 R76 R99 R100 4 51940423741 szaKigaw R72 R900 19400 1501 1 5k 1 4w 5 R77 519400 2211 2 21k 1 4W 43 R82 R175 R177 19400 1301 1 3K 1 4W R78 R113 R114 R159 19400 1211 1 21K 1 4W R79 R83 R155 R167 4 51940422213 oo RB0 R89 muzos2riguzz 123 4 sr9
66. 4ooczemz 267 ___________ R140 R141 19400 2670 267 1 4W R135 R183 19400 1502 15K 1 4W R176 19400 4750 475 1 4W R129 R184 19400 5621 5 62K 1 4W TP1 TP2 T13640 15 15 X1 X2 515128 16 LINEAR INTEGRATED CIRCUIT 15128 4 15128 13 524085 1 518647 518395 13 w X4 X6 PRECISION OP AMP IC EGULATOR ASBLY 5V REG ASBLY 15128 12 VOLTAGE REGULATOR 515018 18 IC ARRAY CLAMPING M15102 3 RESET UNDERVOLT SENSING CIR SS M15458 2 PWM CONTROLLER I C SS X13 X14 515018 19 DRIVER FET 6A X15 M15105 8 CMOS CONVERTER D A SERIAL 10 BIT SS X10 X16 X11 px x x x S 51015 wn m o 3 5 gt lt 5 olo O o E 5 ele cic 5 pir qa NOTE Lincoln Electric assumes no responsibility for resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the LINCOLN machine ELECTRIC PROCUT 55 G3 ELECTRICAL DIAGRAMS G 9 PC BOARD ASSEMBLY CONTROL G3328 2
67. 719 300812373 SONIONI 10713 16 ZS 137270 9 4 2d Id L 18722 SCHEMATIC PLASMA OUTPUT BOARD LINCOLN 5 G 3 NOL 491Se A 0 uunjeH 201 OOL 49 S 8 N O1 201 uunjeg NOL 4 0 uunjeH 201 uonoes NOL uunjeH DOL adi ELECTRICAL DIAGRAMS G 4 SCHEMATIC POWER PC BOARD dF 9 5136 dV V O10 2 IBY 5 5 gle 212 UNDERVOLTAGE zzl olg PROTECTION Qe C3 Rl 8266 HE RELAY DRIVE 8 gt 252 od olo FROM CONTROL 5 155 5 28 6 3 al gt 8 86 5 T 4 95 4 J na gt D D RECONNECT 7 20 431 a a Q 4 oc 206 58 5 5 m DETECTOR pts a 1N4007 Bae gt CAPACITOR 25 d y 585 5 25 a z S olg C15 28545 H o O16 TRANSFORMER 50 S 782 e I PRIMARY 18 dass s wd gt S amp 2 ugs Bl 2884 ois 32506 FILTER 2 olo NOMINAL CAPACITOR amp X 1 00M 8 s EU g 1 TRANSFORMER ag PRIMARY d 82 gt
68. 85 TACH INPUT _ HUSH gt 7 CDM 5 oc tC MEE Y50URCE ielas A SEK PCS E assy wae 5 2 8 PEG SHE DPTOCOUPLER NC UK i ppe iso oo AMEN _____ 38 fa m ELECTRODE SOLION e 9o RI UA COM nz4 font 18 SENSE AMPS Has C78 RELAY 35 amp lv 14 cons f js T 1 T T E i m 5 PRE EHRRGE DISABLE 3 PRIMARY POWER 16 BON OUTPUT SENSE 0 BOARD ee dice X16 RETRAET ARE 85 d us gt 25 D READY m Lame HIT CC Ter daa EE 332K 5 PE wur QUIS e nag Ras E 76K hu 5 5 E Di ME i RHG Po i 136 2 7 Sm E m N E C 18 8K Y Wcom l mE mU gt p ARLO R33 AK T 1 G PD C I eee Inia 4 THERMAL Apu vendis 55V i m EE Q POWER SUPPLY 1 o i Eu 4 5 4 1
69. AL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manu al 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 test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION The following procedure will aid the technician in removing the output power board for main tenance or replacement Return to Section TOC Return to Master TOC MATERIALS NEEDED 5 16 Nut driver 3 16 Allen type wrench 7 16 Wrench Penetrox A 13 Lincoln E2529 Electrical Joint Compound Phillips head screw driver Torque wrench O Fle g gt 018 5 Return to Section TOC Return to Master TOC PRO CUT 55 LINCOLN amp F 59 F 59 TROUBLESHOOTING amp REPAIR OUTPUT POWER BOARD REMOVAL amp REPLACEMENT continued FIGURE F 21 OUTPUT POWER BOARD REMOVAL Return to Section TOC Return to Master TOC OUTPUT POWER BOARD Return to
70. C O O 0 4 c 2 4 Return to Section Return to Master TOC gt 5 LINE INPUT SWITCH RECTIFIER lim rOd zo COomzzoormzu AIR PRESSURE SWITCH zo 4om Jdozvu SIGNAL OUTPUT CONTROL AUX TRANSFORMER OUTPUT BOARD AND TORCH The output board contains an Insulated Gate Bipolar Transistor IGBT which upon receiving a pilot signal from the control board either enables or disables the current in the pilot winding The cutting and pilot rectifier diodes are also incorporated in the output board There are two diodes for each of the secondary windings There are two P C board mounted current sensors One sensor regulates pilot and cutting current The other sen sor indicates to the control board when and how much current transfers to the workpiece The output board also includes the trigger circuitry the gas solenoid driver the electrode solenoid driver and the torch parts in place circuitry The output choke which is in series with both the pilot cir cuit and the cutting circuit provides current filtering to enhance arc stability The PCT 80 torch uses a patented touch start mechanism that provides superior starting performance over other touch start systems The torch head consists of 3 major parts torch body insulator and piston The i
71. D ADVANTAGES The microprocessor controlled Pro Cut 55 design makes plasma cutting and gouging tasks uncompli cated This list of design features and advantages will help you understand the machine s total capabilities so that you can get maximum use from your machine Light weight and portable design for industrial use e Continuous control 25 55 amps e Reliable touch start mechanism for plasma arc initi ation e Unique microprocessor controlled sequence for safe and consistent starting starting e Rapid arc transfer for fast cutting of expanded metal e High transfer distance for ease of use e Input overvoltage protection e 3 0 second pilot arc e Purge momentary push button e Air regulator and pressure gauge located on the front of machine for convenience e Parts in Place mechanism to detect proper instal lation of consumables and torch e Automatic detection of faulty output control In line coarse air filter e Preflow Postflow timing Preflow is eliminated if arc is re initiated in Postflow e Thermostatic Protection e Solid state overcurrent protection e Works with pure nitrogen for cutting nonferrous materials Reconnectable for 230 VAC or 460 VAC inputs e Quick disconnect torch e Display indicators for machine status e Unique electrode and Vortech nozzle design for optimum cooling and long life e Swirl texture inside Vortech nozzle for better start ing reliabilit
72. E D 1 LOCATION OF INPUT FILTER CAPACITOR TERMINALS POWER BOARD INSULATED GLOVES UPPER CAPACITOR TERMINALS LOWER CAPACITOR TERMINALS POWER RESISTOR INSULATED PLIERS PRO CUT 55 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O O 0 4 c 2 4 Return to Section Return to Master TOC O O 4 gt c 2 4 MAINTENANCE ROUTINE MAINTENANCE 1 Keep the cutting or gouging area and the area around the machine clean and free of combustible materials No debris should be allowed to collect which could obstruct air flow to the machine Every 6 months or so the machine should be cleaned with a low pressure airstream Keeping the machine clean will result in cooler operation and higher reliability Be sure to clean these areas Refer Power Output and Control printed circuit boards and heat sinks Power Switch Main Transformer Input Rectifier Examine the sheet metal case for dents or break age Repair the case as required Keep the case in good condition to insure that high voltage parts are protected and correct spacings are maintained All external sheet metal screws must be in place to insure case strength and electrical ground continu ity Check the air regulator filter to be sure it does not become clogged The air filter on
73. ECTIONS A WARNING ELECTRIC SHOCK can kill Have a qualified electrician install and service this equipment e Turn the input power off at the fuse box before working on this equipment Do not touch electrically hot parts Before installing the machine check that input supply voltage phase and frequency are the same as the machine s voltage phase and frequency as specified on the machine s rating plate See Figure A 1 FIGURE A 1 RATING PLATE LOCATION 1 CASE BACK 2 RATING PLATE 3 POWER CORD CONNECTOR WITH STRAIN RELIEF The Pro Cut 55 should be connected only by a quali fied electrician Installation should be made in accor dance with the U S National Electrical Code all local codes and the information detailed below GROUND CONNECTION The frame of the Pro Cut 55 must be properly ground ed ground terminal marked with the symbol is mounted on the case bottom directly behind the input power switch for this purpose The ground lead of the input power cord that is attached to the machine must be connected to this ground terminal See the National Electric Code for details on proper grounding methods Install in accordance with all local and national electrical codes INPUT POWER CORD CONNECTOR INSTALLATION The Pro Cut 55 is supplied with one 11 foot 3 35m 8 AWG 3 lead input power cord already connected to the machine A cord connector provides a strain relief for the
74. Ea F 2 How to Use Troubleshooting nennen nnne nnn nnn nnne nnn nnns F 2 Troubleshooting 4 Test Procedures F 14 Replacement Procedures Me F 50 Electrical B 5 ETE Section G Parts Manual S P309 Series amp P210 K PRO CUT 55 LINCOLN amp Section A 1 Section A 1 TABLE OF CONTENTS INSTALLATION SECTION D v Installation 9 c SSC c 2 2 9 4 Select Suitable LOC ANON TM 4 127541179 m 4 in ana MOVIN 5 2 c 4 Wal 4 High Frequency Interference 4 OUT Electrical amp 5 Connection 5 Input Power Cord Connector A 5 input Wire and Fuse SIZE A 5 piense A 6 2 2 Gas ___ ____________ __ 7 Connec HONS 8 Toreh COMMS CTO
75. GE Provides gas pressure reading as set by the gas regulator knob GAS PURGE BUTTON Used to check or set gas pressure Push in and hold to check pressure then continue to hold to set the pressure Shuts off gas when released RESET BUTTON Used to reset the machine fol lowing a safety circuit trip STATUS DISPLAY BOARD INDICATORS Four lights indicating Power Gas Low Thermal and Safety PILOT ARC CONSIDERATIONS The Pro Cut has a smooth continuous pilot arc The pilot arc is only a means of transferring the arc to the workpiece for cutting Repeated pilot arc starts in rapid succession is not recommended as these starts will generally reduce consumable life Occasionally the pilot arc may sputter or start intermittently This is aggravated when the consumables are worn or the air pressure is too high Always keep in mind that the pilot arc is designed to transfer the arc to the work piece and not for numerous starts without cutting When the pilot arc is started a slight impulse will be felt in the torch handle This occurrence is normal and is the mechanism which starts the plasma arc This impulse can also be used to help troubleshoot a no start condition CUTTING OPERATION When preparing to cut or gouge position the machine as close to the work as possible Make sure you have all materials needed to complete the job and have taken all safety precautions lt is important to follow these operating steps ea
76. Gee oT 126 8 96 5 35V of 01 _ 1 R33 e i e el com L P SUI SHORT TEMP OX H AIR SOLENOLO ___ MRSSILEHOID 155y OENE OVERTE s iv PILOT SWITCH 02 COM wk M ze us Js z RES i THERMOSTAT OK an ELECTRODE SOLENDIO EA 22222 __ ELECTRODE SGLENOID c gt COM COM CONTROL POT 47 gz Uo ooo Mua o 2 mw _ m pes 42_ MERE TN TOP REIN POEM JE Eu P mE o 188 heh as Ge OPERI S ERU RE E 7 _ FSBFETY RE T Pow PE SAFETY 7 n i ai D28 pe a Cs RBG _ 291 06 a pe Ain LOM i Mem cus X sop genus PRESSURE ER VOLTAGE 45 peg 38 THERMAL Er T o gt CN ag pes 44 MEM SON IGET DRIVE i 24 PI PAL a MEME ELECTRODE AMPS 45 as rur A i RETRACT 32 pan Pia P c TACH INPUT Nc ONERE RETE LUE 21 5 5 v 24 le MC Es T Pas mana 3 COM 3 12 MIE XIE ed eee il GNU 1 8 Pos PRS I TE GND prd T PRIMARY CAP 181
77. IFICATION C1 C2 C3 C4 4 S16668 4 2700pF 50 COMPONENT SIDE OPPOSITE COMPONENT SIDE C5 1 S13490 25 4 7 35 2 CIRCUITRY MULTIPLE CIRCUITRY MULTIPLE DZ1 1 T12702 27 1N4740 2 LED1 1 18875 1 LIGHT BAR LED YELLOW E N B LED2 LED7 2 M18875 5 LIGHT BAR LED RED N B LED3 LED6 2 M18875 2 LIGHT BAR LED RED a a LED4 1 M18875 6 LIGHT BAR LED YELLOW Q 52 N B LED5 1 M18875 3 LIGHT BAR LED YELLOW a eu N B LED8 1 M18875 7 LIGHT BAR LED GREEN o X ae 2 NX 1229896 O Qm ooo E N B LED9 1 M18875 4 LIGHT BAR LED GREEN 992 55 0200595 200 20229 65 SUE 9999 f 01 02 03 04 4 T12704 68 2 4401 oO Dr x P gene ua R1 R5 R9 R13 4 519400 3321 3 32 1 4W g E A 2 dude ce 990 ARA M bs R2 R6 R10 R14 4 S19400 6811 _ 6 81 1 4W es f DISPLAY o Nooo LLL oc 5 oO R3 R4 R7 R8 R11 R12 6 519400 1000 100 1 4W 2 R15 R16 2 519400 7580 75 1 4 17 1 519400 8250 825 1 4W st R18 R19 2 19400 2671 2 67 1 4W 619 R20 1 19400 2430 243 1 4W lt 9 E Fo cix rii 0 9 BLANK PART NO L10721 A mo 95 918 MAKE FROM 519399 22 MAKES 24 BOARDS 2 5 uo 9 in NOTE BLANK SHEARING TOLERANCE SEE P C BOARD ASSEMBLY E c c ram 5 D ITEM REQ D PART NO IDENTIFICATION cc 1 1 SEE BLANK P C
78. O c 4 0 4 2 Return to Master 4 4 75K TM lt 6 uova etes Peces etn i EAN FROL POT a a 35 wa PRIMARY CURREHT 1 FW 3 t 5 35 Yeon Yin p conp Xi 154 uli d acad T 1 PURGE SHORT TAIGBER GW a COM du 2 ser TM 1 8K y PUSHBUTTON TRIGGER EIRCUIT i 5 5 4 6 5638465 4 TRIGGER ON TRIGCER OFF a L 5 IER e Siri yd CN i Z SAFETY reset cam Shutdesn 825 E Arps 9 25 1182 _FUSHAUTFON
79. OC Return to Master TOC Return to Section TOC O Fle Cc Ix gt 018 5 4 cc Return to Section TOC Return to Master TOC Return to Master TOC E 9 E 9 THEORY OF OPERATION PULSE WIDTH MODULATION The term PULSE WIDTH MODULATION describes how much time is devoted to conduction in the posi tive and negative portions of the cycle Changing the pulse width is known as MODULATION Pulse Width Modulation PWM is the varying of the pulse width over the allowed range of a cycle to affect the output of the machine MINIMUM OUTPUT By controlling the duration of the gate signal the IGBT is turned on and off for different durations during a cycle The top drawing below shows the minimum output signal possible over a 50 microsecond time period The positive portion of the signal represents one IGBT group conducting for 1 microsecond The negative portion is the other IGBT group The dwell time off time is 48 microseconds both IGBT groups off Since only 2 microseconds of the 50 microsecond time period is devoted to conducting the output power is minimized MAXIMUM OUTPUT By holding the gate signals on for 22 microseconds each and allowing only 3 microseconds of dwell time off time during the 50 microsecond cycle the output is maximized The darkened area under the top curve can be compared to the area under the bottom curve The more dark area under the curve the mor
80. Section TOC Return to Master TOC PROCEDURE 1 Remove input power to the Pro Cut 55 3 Locate the output power P C board and machine associated lead and plug connections See 2 Remove the case wraparound and perform Figures 221 and 22 the Input Capacitor Filter Discharge detailed earlier in this section O Fle C gt 0218 5 cc Return to Section TOC Return to Master TOC PRO CUT 55 LINCOLN amp F 60 F 60 TROUBLESHOOTING amp REPAIR OUTPUT POWER BOARD REMOVAL amp REPLACEMENT continued FIGURE F 22 OUTPUT BOARD LEAD LOCATIONS Return to Section TOC Return to Master TOC 63326 1 PRO CUT 55 OUTPIUT Return to Master TOC Return to Section TOC 4 Using the 7 16 wrench remove leads X4 X2 9 Carefully remove the output power board and B21 from the output power board from the heat sink 5 Remove all plugs from the output power board CAUTION 6 Remove leads X20 and X40 from the output power board Be sure to follow the recommended static free methods for handling printed circuit boards 7 Using the phillips head screw driver remove Failure to do so can result in permanent damage the two screws from the lower left and right the equipment corners of the ou
81. Solenoid Test 2 Perform the Low Voltage 3 4 Circuit Test The output board may be faulty Perform the Output Board Resistance Test he control board may be faulty Replace CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 PRO CUT 55 LINCOLN amp F 6 F 6 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual PROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENT S RECOMMENDED COURSE OF ACTION Return to Section TOC Return to Master TOC Return to Section TOC O Fle g gt 3 5 4 x Return to Section TOC Return to Master TOC Return to Master TOC The air begins to flow when the torch trigger is pulled There is a very brief pilot arc Normal is 3 seconds The sequence is repeat ed with subsequent trigger pulls FUNCTION PROBLEMS Make sure the air pressure is set at 70 psi 448 kPa and the flow rate is at 6 CFM Make sure the torch consum ables are in place and in good condition Make sure the air flow is not restricted Make sure the air hose and The cutting arc starts but sputters badly screen are not clogged
82. T Y YELLOW FOR THREE PHASE INPUT GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES J4 J6 sls CONNECT TERMINALS U V amp W TO SUPPLY CIRCUIT J3 J2 J8 J31 41 120 0730 J5 J32 Olg N B SINCE COMPONENTS OR CIRCUITRY OF A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING 12 Ee p 2 THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY NOT SHOW THE EXACT 2 22 22 pA DOG RE PE dea dee COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER 52 2 gt 34 08 2 gt N C PLACE A LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE CONNECTION SHOWN IS FOR 440 460V OPERATION CONNECTOR CAVITY NUMBERING SEQUENCE 515 ELECTRICAL SYMBOLS PER E1537 VIEWED FROM COMPONENT SIDE OF BOARD 5 110634 8 7 98 cc NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine PROCUT 5 G 3 PROCUT 55 22101 71 709 905 405 exc 5175 5 50 734 wW L SOUVONVIS ger 169 am AX Pe v tio fart uw 5 338930 9 30 S 1 STONY TW NO 01 HOMOd W JILYWSHIS alia OIHO ONV13432 Queens 200 51 SWHIISD 39574 NO 267 Pe Jog JIMLIZT3 34 ase 3 uad 27 rji 9802
83. TOC Return to Master TOC Return to Section TOC Return to Master TOC O Fle C Ix gt 0218 5 4 cc Return to Section TOC Return to Master TOC F 63 F 63 TROUBLESHOOTING amp REPAIR PRIMARY POWER BOARD AND FILTER CAPACITOR REMOVAL AND REPLACEMENT continued FIGURE F 23 PRIMARY POWER BOARD REMOVAL REMOVAL PROCEDURE 1 Remove input power the Pro Cut 55 machine Hemove the case wraparound and perform the Filter Capacitor Discharge Procedure detailed earlier in this section Locate the primary power board and associ ated lead and plug connections See Figure F 23 PRO CUT 55 LINCOLN amp PRIMARY POWER BOARD WITH INPUT FILTER CAPACITORS Label the leads for reassembly 5 Remove Plug J10 m Using the 7 16 wrench remove leads 201 202A 203A 204 205 206 207A 208 and 209 Return to Section TOC Return to Master TOC Return to Section TOC O Fle E 1 gt 3 5 4 cc Return to Section TOC Return to Master TOC Return to Master TOC F 64 F 64 TROUBLESHOOTING amp REPAIR PRIMARY POWER BOARD AND FILTER CAPACITOR REMOVAL AND REPLACEMENT continued FIGURE F 24 POWER BOARD HEATSINK AND CAPACITOR REMOVAL CAPACITOR 227 CLAMP PRIMARY POWER 7 16 CAPACITOR BOLT 4 INSULATOR 2 MOUNTING SCREW 2 7 Using the slot head s
84. The control board may be faulty Replace Perform the Torch Continuity and Solenoid Test Check leads E 364 and 4369 between the torch receptacle and the output board See the Wiring Diagram The output board may be faulty Replace The reset button or associated wiring may be faulty See the Wiring Diagram Perform the Torch Continuit and Solenoid Test The control board may be faulty Replace If the machine operates normal ly with the Safety LED on the display board may be faulty Replace A CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 PRO CUT 55 LINCOLN F 9 F 9 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual PROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENT S LED FUNCTION PROBLEMS RECOMMENDED COURSE OF ACTION Return to Section TOC Return to Master TOC The Thermal LED is lit 1 One of the machine s ther mostats has tripped Do not turn the Pro Cut 55 off Allow the machine to cool The ther mostat s will reset themselves The thermostat may be faulty Replace The control board may be faulty Replace If the machine operates normal
85. YOUR BARE HANDS Repeat the discharge procedure for the capacitor on the other two terminals Check the voltage across the terminals of all capacitors with a DC voltmeter Polarity of the capacitor terminals is marked on the PC board above the terminals Voltage should be zero any voltage remains repeat this capacitor discharge procedure FIGURE 1 LOCATION OF INPUT FILTER CAPACITOR TERMINALS INPUT POWER BOARD INSULATED GLOVES PRO CUT 55 LINCOLN amp UPPER CAPACITOR TERMINALS LOWER CAPACITOR TERMINALS POWER RESISTOR INSULATED PLIERS Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O Fle g gt 018 5 Return to Section TOC Return to Master TOC F 14 TROUBLESHOOTING amp REPAIR INPUT RECTIFIER TEST A WARNING Service and repair should be performed by only Lincoln Electric factory trained person nel Unauthorized repairs performed on this equipment may result in danger to the tech nician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before
86. above the workpiece during cutting Do not let the torch nozzle touch the work or carry a long arc e Keep moving while cutting Cut at a steady speed without pausing Maintain the cutting speed so that the arc lag is 10 to 20 behind the travel direction e Use a 5 15 leading angle in the direction of the cut e Use the drag cup to maintain constant standoff for better cut quality and to protect the nozzle from spatter e Use the drag cup with a metal template to prevent nozzle double arcing 5 15 Leading Angle gt Direction of Travel 10 Arc Lag e Finish the cut to be made and release the trigger e When the trigger is released the arc will stop The gas will continue to flow for 10 seconds of postflow If the trigger is activated within this time period the pilot arc will immediately restart e f the dross is difficult to remove reduce the cutting speed High speed dross is more difficult to remove than low speed dross e The right side of the cut is more square than the left as viewed along the direction of travel e Clean spatter and scale from the nozzle and drag cup frequently For gouging tilt the torch about 45 from the work piece and hold the nozzle 1 8 in 3 2mm to 3 16 4 7mm above the workpiece ANGLE OF APPROACH TORCH HELD AT 45 ANGLE THROUGHOUT GOUGE ANGLE MAINTAINED SAFETY STATUS INDICATOR e f the SAFETY status indic
87. ad 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 oylin ders associated equipment and CGA publication P l Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 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 local codes and the manufacturer s rec ommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations PLASMA ARC can injure 7 a Keep your body away from nozzle and plasma arc 7 6 Operate the pilot arc with caution The pilot arc is capable of burning the operator others or even piercing safety clothing ELECTRIC AND MAGNETIC FIELDS may be dangerous 3 N 8 a Electric current flowing through any conduc S N tor causes localized Electric and Magnetic Fields EMF Cutting or gouging current creates EMF fields around torch cables and cutting machines 8 b EMF fields may interfere with some pace makers so operators having a pacemaker should consult their phys
88. al trou bleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION The following procedure will aid the technician in removing the display board for maintenance or replacement MATERIALS NEEDED 5 16 Nut driver Screw driver PRO CUT 55 LINCOLN amp F 54 F 55 F 55 TROUBLESHOOTING amp REPAIR DISPLAY BOARD REMOVAL amp REPLACEMENT continued FIGURE F 19 CASE FRONT SCREW REMOVAL Return to Section TOC Return to Master TOC 4 SCREWS Return to Section TOC Return to Master TOC PROCEDURE 1 Remove the input power to the Pro Cut 55 4 Carefully slide do not force the front away machine from the rest of the machine about one inch This will allow more working room to 2 Remove the wraparound cover and perform the Input Filter Capacitor Discharge remove the display board detailed earlier in this section 3 Using the 5 16 nut driver remove the four screws holding the front assembly to the top and base of the machine See Figure F 19 O Fle C gt 9 9 5 cc Return to Section TOC Return to Master TOC PRO CUT 55 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC O Fle Cc xXx gt 0218 5 4 cc Return to Section TOC Return to Master TOC Return to Master TOC F 56 F 56
89. and nuts to 44 in lbs Return to Section TOC Return to Master TOC 9 Reconnect the 10 leads to the correct ter minals and torque the phillips head screws to 31 in lbs 10 Apply Essex DC 4 8 Insulating Com pound to all six screw heads and termi nals The heavy input lead terminals should be against the rectifier terminals Return to Section TOC Return to Master TOC O Fle Cc gt 0218 5 4 cc Return to Section TOC Return to Master TOC PRO CUT 55 LINCOLN amp Return to Section TOC Return to Master TOC Return to Section TOC O Fle Cc gt 0218 5 4 x Return to Section TOC Return to Master TOC Return to Master TOC F 69 F 69 TROUBLESHOOTING amp REPAIR RETEST AFTER REPAIR Should a machine under test be rejected for any reason requiring the removal of any mechanical part that could affect the machine s electrical characteristics or if any electrical components are repaired or replaced the machine must be retested INPUT IDLE AMPS AND WATTS Output Current Range 25 55 Amps Maximum Open Circuit Voltage 335 Volts PRO CUT 55 LINCOLN F 70 LINCOLN amp NOTES PRO CUT 55 F 70 NOL 491Se A 0 uunjeH 901 491Se A 0 uunjeH NOL J91Se AN 0 uunjeH NOL uunjeH DOL uonoes DOL uonoes uunjeg DOL DOL
90. ar hydraulic lines Have a fire extinguisher readily available Where compressed gases are to be used at the job site spe cial precautions should be used to prevent hazardous situa tions Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used When not cutting or gouging make certain no part of the elec trode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not cut or gouge tanks drums or containers until the prop er steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping 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 gouging They may explode Do nor fuel engine driven equipment near area where plasma cutting or gouging PRO CUT 55 LINCOLN Return to Master TOC Return to Master TOC O O 4 gt c 2 4 Return to Master 4 0 Sparks and spatter are thrown from the plasma arc Wear safe ty glasses ear protection and oil free protective garments
91. arity markings and terminal position CAPACITOR REPLACEMENT AND P C BOARD REPLACEMENT 1 Replace the capacitors by positioning them in the clamps Do not tighten the clamps They must be loose when the P C board is assembled to the capacitors Apply a thin coating of Penetrox A 13 Electrical Joint Compound to the mating sur faces of the P C board and the heat sink and capacitor terminals Mount the P C board to the heat sink and capacitor assembly Make sure the capacitor terminals line up with the holes in the P C board and with the correct capacitor polari ties 10 11 12 13 14 15 16 Assemble the four socket head screws and pre torque them to 25 inch pounds Make certain the capacitors are lined up correctly so that when the capacitor bolts are assembled through the P C board there will NOT be any distortion to the P C board Finish tightening the four screws to 40 48 inch pounds Assemble the two slot head screws with their appropriate insulators Tighten the capacitor clamps Place the assembly into the machine and connect the two thermostat leads previous ly removed Secure the assembly to the upper and bot tom sections of the unit using the 3 8 wrench and the four screws previously removed Connect the J10 plug Connect leads 201 204 205 208 and 209 previously removed Connect leads 202A 207A 206 and 203A to the capacitor terminals Torque to 50 60
92. ates that the 5 5 VDC is present This voltage is derived from the 15 VDC supply The 5 5 VDC supply is used to power the circuitry on the control board LED3 Red This light indicates that 18 VAC is being supplied to the control board from the auxiliary transformer It also shows that the 18 VAC is being rectified and should be regulated to 15 VDC This 15 VDC supply is used to power the circuitry on the control board FIGURE 15 DISPLAY BOARD TEST POINTS L10721 DISPLAY BOARD REAR VIEW PRO CUT 55 LINCOLN F 49 LINCOLN amp NOTES PRO CUT 55 F 49 NOL 491Se A 0 uunjeH 901 491Se A 0 uunjeH NOL J91Se AN 0 uunjeH NOL uunjeH DOL uonoes DOL uonoes uunjeg DOL DOL Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O Fle g gt 018 5 Return to Section TOC Return to Master TOC F 50 TROUBLESHOOTING amp REPAIR CONTROL BOARD REMOVAL AND REPLACEMENT A WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed t
93. ators light at any time check the following Check the assembly of the torch consumables If they are not properly in place the machine will not start Make sure that the shield cup is hand tight Do not use pliers or over tighten PRO CUT 55 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O Fle Cc gt 0218 5 4 x Return to Section TOC Return to Master TOC B 7 B 7 OPERATION WARNING ELECTRIC SHOCK can kill e Turn off machine at the disconnect switch on the front of the machine before tightening cleaning or replac ing consumables Check the conditions of the inside of the nozzle If debris has collected rub the electrode on the inside bottom of the nozzle to remove any oxide layer that may have built up Refer to Suggestions for Extra Utility from the Pro Cut Check the condition of the electrode If the end has a crater like appearance replace it along with the nozzle The maximum wear depth of the electrode is approximately 062 in 1 6mm A green and erratic arc will indicate definite electrode failure The electrode should be replaced immediately e Replace the nozzle when the orifice exit is eroded away or oval shaped e After the problem is found or if there is nothing apparently wrong reset the machine by pressing the Reset button It is possible for elect
94. ays wear dry insulating gloves Turn the 55 Power Switch OFF when connecting power cord to input power Only qualified personnel should install use or ser vice this equipment SELECT SUITABLE LOCATION Place the Pro Cut 55 where clean cool air can freely circulate in through the rear louvers and out through the front bottom opening Dirt dust or any foreign material that can be drawn into the machine should be kept at a minimum Failure to observe these precau tions can result in excessive operating temperatures and nuisance shutdown of the machine A source of clean dry air or nitrogen must be supplied to the Pro Cut 55 Oil in the air is a severe problem and must be avoided The supply pressure must be between 80 and 150 psi The flow rate is approximate ly 6 0 cfm 170 Failure to observe these pre cautions could result in excessive operating tempera tures or damage to the torch STACKING The Pro Cut 55 cannot be stacked LIFTING AND MOVING A WARNING FALLING EQUIPMENT can cause injury e Do not use the pull handle on the optional undercarriage if installed to lift the machine This handle is not designed to support the full weight of the machine Using it to lift the machine could cause per sonal injury or damage to the machine e Either the front or rear handles or both may be used to lift or move the machine TILTING The Pro Cut 55 must be placed on a stable level sur
95. ce circuit safety status indicator light continues to trip after cleaning the consum ables replace them with a new set Do not contin ue to cut with excessively worn consumables as this can cause damage to the torch head and will degrade cut quality To improve consumable life here are some sug gestions that may be useful a Never drag the nozzle on the work surface if the output control knob is above the mid range setting b Make sure the air supply to the Pro Cut is clean and free of oil Use several extra in line filters if necessary Use the lowest output setting possible to make a good quality cut at the desired cut speed d Minimize dross buildup on the nozzle tip by starting the cut from the edge of the plate when possible e Pierce cutting should be done only when nec essary If piercing angle the torch about 30 from the plane perpendicular to the work piece transfer the arc then bring the torch perpendicular to the work and begin parallel movement f Reduce the number of pilot arc starts without transferring to the work g Reduce the pilot arc time before transferring to the work h Set air pressure to recommended setting A higher or lower pressure will cause turbulence in the plasma arc eroding the orifice of the nozzle tip i Use only Lincoln consumable parts These parts are patented Using any other replace ment consumables may cause damage to the torch or reduce cut quality
96. ch time you use the machine e Turn the machine s ON OFF POWER SWITCH to the OFF position e Connect the air supply to the machine e Turn the main power and the machine power switch on fan should start The pre charge circuit will operate for 3 seconds then the green Power status indicator should turn on f the SAFETY status indicator is lit push the Reset button If there is no problem the status indicator will go off If there is a problem refer to STATUS INDICATOR in this section e Be sure that the work lead is clamped to the work piece before cutting e Set the output current control knob for maximum current for high cutting speed and less dross forma tion per Figure B 1 Reduce the current if desired to reduce the kerf cut width heat affected zone or travel speed as required e Push in and hold the Purge button to check or set the gas pressure Pull the pressure regulator cap out and turn it to set the pressure Adjust the gas regulator for 70 PSI for 25 foot 7 62m torches or 75 PSI for 50 foot 15 24m torches Release the Purge button PRO CUT 55 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O O c 42 0 c 2 4 Return to Section Return to Master TOC O O gt c See 2 rm OPERATION The gas will immediately turn
97. crew driver remove the 9 Carefully remove the primary power board two mounting screws from the left side of the from the heat sink primary power board See Figure F 24 Take note of insulator placement for reassembly A CAUTION the four socket head screws and lock wash Be sure to follow the recommended static free ers mounting the primary power board to the methods for handling printed circuit boards heat sink Failure to do so can result in permanent damage 8 Using the 3 16 allen type wrench remove to the equipment PRO CUT 55 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O Cc gt 0218 5 4 oO x 65 65 TROUBLESHOOTING 8 REPAIR PRIMARY POWER BOARD AND FILTER CAPACITOR REMOVAL AND REPLACEMENT continued CAPACITOR REMOVAL 1 Using the 3 8 wrench remove the four screws holding the heat sink assembly to the upper and bottom sections of the machine Seo Figure F24 Remove the gas hose restraints from the bot tom of the heat sink assembly Remove the two thermostat leads from the thermostat which is located next to the upper capacitor Carefully remove the heat sink and capacitor assembly Clear any necessary leads Remove the faulty capacitors by using the slot head screw driver to loosen the clamps Take note of capacitor position in the clamp Observe pol
98. ds 9 Clear and secure all leads and replace the wraparound cover PRO CUT 55 LINCOLN amp F 61 F 62 F 62 TROUBLESHOOTING amp REPAIR PRIMARY POWER BOARD AND FILTER CAPACITOR REMOVAL AND REPLACEMENT A WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manu al 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 test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION The following procedure will aid the technician in removing the primary power board and fil ter capacitors for maintenance or replacement Return to Section TOC Return to Master TOC MATERIALS NEEDED 5 16 Nut driver 3 16 Allen type wrench 7 16 Wrench Slot Head screw driver Torque wrench 3 8 Wrench Penetrox A 13 Lincoln E2529 Electrical Joint Compound O Fle g gt 018 5 Return to Section TOC Return to Master TOC PRO CUT 55 LINCOLN amp Return to Section
99. ds please use the following procedure 1 Determine to the best of your technical ability that the PC board is the most likely component causing the failure symptom 2 Check for loose connections at the PC board to assure that the PC board is properly connected If the problem persists replace the suspect board using standard practices to avoid static electrical damage and electrical shock Read the warning inside the static resistant bag and perform the following procedures PC board can be damaged by static electricity Remove your body s static charge before opening the static shielding bag Wear an anti static wrist strap For safety use a 1 Meg ohm resistive cord connected to a grounded part of the equipment frame ATTENTION Static Sensitive If you don t have a wrist strap touch an un painted grounded part of the equipment frame Keep touching the frame to prevent static build up Be sure not to touch any electrically live parts at the same time Tools which come in contact with the PC board must be either conductive anti static or static dissipative Remove the PC board from the static shielding bag and place it directly into the equipment Don t set the PC board on or near paper plastic or cloth which could have a static charge If the PC board can t be installed immediately put it back in the static shield ing bag f the PC board uses protective shorting jumpers don t remove
100. e Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION This test will help the technician determine if the output power board is faulty Return to Section TOC Return to Master TOC MATERIALS NEEDED 5 16 Nut driver Analog Volt ohmmeter 7 16 Wrench O Fle g gt 018 5 Return to Section TOC Return to Master TOC PRO CUT 55 LINCOLN amp Return to Section TOC Return to Master TOC Return to Section TOC O o C Ix gt 0218 5 4 cc Return to Section TOC Return to Master TOC Return to Master TOC F 25 F 25 TROUBLESHOOTING amp REPAIR OUTPUT POWER BOARD RESISTANCE TEST continued FIGURE F 4 OUTPUT POWER BOARD LEAD LOCATIONS PRO CUT 55 OUTPIUT eo 2 J is re Poi 93326 1 only Test Point G3326 2 3 TEST PROCEDURE 1 Remove input power to the Pro Cut 55 4 Remove leads X4 X2 B21 X20 X40 and machine plugs J33 and J32 from the output power 2 Perform the Input Filter Capacitor Discharge Procedure detailed earlier in this 5 Using the analog ohmmeter perform the Table 4 section resistance checks per 3 Remove the torch assembly f
101. e observe all safety notes and precautions detailed throughout this manu al If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION The test will determine if the auxiliary transformer is functional when the correct primary volt age is applied to the primary winding MATERIALS NEEDED Volt ohmmeter Machine wiring diagram 5 16 Nut driver 230 VAC isolated power supply PRO CUT 55 LINCOLN 5 F 34 F 35 F 35 TROUBLESHOOTING amp REPAIR T2 AUXILIARY TRANSFORMER TEST continued c 5 2 FIGURE F 8 T2 AUXILIARY TRANSFORMER 9 3 o 2 dz 5 9 4 8 2 6 PLUG 21 alo PLUG J21 H5 6 rs 2 H3 X PLUG 22 H2 4 1 H1 0 0 512 T2 AUXILIARY PLUG 22 10 Cavity gt TRANSFORMER 2 5 8 4 7 2 2 cc H2 5 1 H1 PLUG J 22 8 Cavity PROCEDURE 1 Remove main input power to the Pro Cut 55 5 Carefully apply the 230 VAC isolated supply machine to leads H1 1J22 and 2422 of the aux 2 Perform the Input Filter Capacitor s xo mee These leads are located in Discharge Procedure detailed earlier in this pug section
102. e power is present 1 An IGBT group consists of two IGBT modules feeding one transformer primary winding FIGURE E 8 TYPICAL IGBT OUTPUTS 1 usec 22 48 1 usec 50 u sec MINIMUM OUTPUT gt 22 5 1 50 MAXIMUM OUTPUT PRO CUT 55 LINCOLN amp E 10 LINCOLN amp NOTES PRO CUT 55 E 10 NOL 491Se A 0 uunjeH 901 491Se A 0 uunjeH NOL J91Se AN 0 uunjeH NOL uunjeH DOL uonoes DOL uonoes uunjeg DOL DOL Return to Master TOC Return to Master TOC O O 4 gt c 2 4 Return to Master Section F 1 TABLE OF CONTENTS TROUBLESHOOTING amp REPAIR SECTION Troubleshooting amp Repair 4 2 2 22 Section F How to Use Troubleshooting Guide nennen nennen nnn nnn nnns F 2 PC Board Troubleshooting Procedures and Replacement F 3 OUTING c P F 4 Test Procedures Troubleshooting Flow Ae F 10 Input Filter Capacitor Discharge nnne F 12 TeSt F 14 Primary Power Board Resistance Test and Capacitor Voltage
103. econnection will be necessary if a higher input voltage is used To reconnect the Pro Cut to 460 VAC or to connect back to 230 VAC follow the directions as outlined below Follow this procedure ONLY while the Pro Cut is dis connected from the input power CAUTION Failure to follow these instructions can cause immedi ate failure of components in the welder 1 Open the access door on the back of the machine Connection instructions are also included on the inside of the door 2 For 230 Position the large switch to 200 230 See Figure A 2 For 460 Position the large switch to 380 460 See Figure A 2 3 Move the A lead to the appropriate terminal RECONNECT PROCEDURE WARNING Disconnect input power before inspecting or servicing machine Do not operate with wraparound removed Do not touch electrically live parts Only qualified persons should install use or service this equipment 1 BE SURE POWER SWITCH IS OFF 2 CONNECT LEAD A TO DESIRED INPUT VOLTAGE RANGE 440 460V 380 415V 220 230V 200 208V 3 POSITION SWITCH TO DESIRED INPUT VOLTAGE RANGE 8 1 VOLTAGE 380 460V 9 ng 1 VOLTAGE 200 230V PRO CUT 55 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC O Fle Cc xXx gt 0218 5 4 cc Return to Section TOC Return to Master TOC Return to Master TOC
104. han 100 ohms Greater than 1000 ohms Less than 100 ohms Greater than 1000 ohms Less than 100 ohms Greater than 1000 ohms Less than 100 ohms Greater than 1000 ohms Less than 100 ohms Greater than 1000 ohms Less than 100 ohms Greater than 1000 ohms Less than 100 ohms If the power board passes the resistance test the IGBT portion of the board is good However other circuits on the power board may be faulty These circuits are NOT readi ly tested or serviceable Reconnect leads 201 204 205 and 208 to their appropriate terminals PRO CUT 55 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC O Fle C Ix gt 018 5 4 t cc Return to Section TOC Return to Master TOC Return to Master TOC F 21 TROUBLESHOOTING amp REPAIR PRIMARY POWER BOARD RESISTANCE TEST AND CAPACITOR VOLTAGE TEST continued CAPACITOR VOLTAGE TEST This test will help the technician to determine if the input filter capacitors are being charged equally to the correct voltage levels NOTE This test should only be conducted with the Pro Cut 55 connected for 400 VAC and above and with the appropriate input voltage applied TEST PROCEDURE 1 Remove main input power to the Pro Cut 55 2 Perform the Input Filter Capacitor Discharge Procedure detailed earlier in this section 3 Locate and familiarize yourself with the capacitor te
105. hlights For additional safety information it is strongly recommended that you pur chase a copy of Safety in Welding amp Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 BE SURE THAT ALL INSTALLATION PERFORMED ONLY BY QUALIFIED INDIVIDUALS 1 e ELECTRIC SHOCK can kill 1 a The electrode and work or ground circuits are electrically hot when the power source is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insu late hands When the power source is operating voltages in excess of 250 volts are produced This creates the potential for serious elec trical shock potentially even fatal Insulate yourself from work and ground using dry insulation When cutting or gouging in damp locations on metal frame work such as floors gratings or scaffolds and when in posi tions such as sitting or lying make certain the insulation is large enough to cover your full area of physical contact with work and ground Always be sure the work cable makes a good electrical con nection with the metal being cut or gouged The connection should be as close as possible to the area being cut or gouged Ground the work or metal to be cut or gouged to a good elec trical earth ground 1 f Maintain the plasma torch cable and work clamp in good safe 1 g 1 h operating condition Rep
106. hroughout this manu al If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION The following procedure will aid the technician in removing the control board for maintenance or replacement MATERIALS NEEDED 5 16 Nut driver Needle nose pliers PRO CUT 55 LINCOLN F 50 F 51 F 51 TROUBLESHOOTING amp REPAIR CONTROL BOARD REMOVAL AND REPLACEMENT continued FIGURE F 16 CASE FRONT SCREW REMOVAL Return to Section TOC Return to Master TOC 4 SCREWS EIE 5 5 0 g gt ele 5 5 ac PROCEDURE 1 Remove input power to the Pro Cut 55 3 Using the 5 16 nut driver remove the four machine screws holding the front assembly to the top 2 Remove the wraparound cover and perform and base of the machine See Figure F 16 the Filter Capacitor Discharge 4 Carefully slide do not force the front away Procedure detailed earlier in this section from the rest of the machine about one inch This will allow more working room to remove the control board FIGURE F 17 CONTROL BOARD MOLEX PLUG REMOVAL O Cc xXx gt 3 5 4 oO cc MOLEX PLUGS 5
107. ician before cutting or gouging 8 c Exposure to EMF fields during cutting or gouging may have other health effects which are now not known 8d All operators should use the following procedures in order to minimize exposure to EMF fields from the cutting or gouging circuit 8 d 1 Route the torch and work cables together Secure them with tape when possible 8 d 2 Never coil the torch cable around your body 8 d 3 Do not place your body between the torch and work cables If the torch cable is on your right side the work cable should also be on your right side 8 d 4 Connect the work cable to the workpiece as close as possible to the area being cut or gouged 8 d 5 Do not work next to cutting power source Apr 93 PRO CUT 55 LINCOLN NOTES NOL 491Se A 0 uunjeH NOL 491se N 01 uunjeH NOL ISEN 0 uunjeH PRO CUT 55 LINCOLN E NOL uunjeH MASTER TABLE OF CONTENTS FOR ALL SECTIONS RETURN MAIN MENU Page i iii aeee E EE E T E E Section A 8 Section B RE E Section C ANS Oss RETE Section D Theory of Operation 2 2 c i d acra a s ar a aa d Section E Troubleshooting and nennen nennen nnne Section F oateby Prec ______ _ EE D T ipR
108. ill maintain the prop er standoff The only time not to use the drag cup when the output control is set above mid range is in special tight corners Always hold at least a 1 8 in 3 2mm standoff in those situations If piercing is required slowly lower the torch at an angle of about 30 to blow the dross away from the torch tip and slowly rotate the torch to a vertical position as the arc becomes deeper This process will blow a lot of molten metal and dross Be care ful Blow the dross away from the torch the opera tor and any flammable objects Where possible start the cut from the edge of the workpiece Keep moving A steady speed is necessary Do not pause Do not allow the torch cable or body to contact a hot surface SUGGESTIONS FOR EXTRA UTILITY FROM THE PRO CUT SYSTEM WARNING ELECTRIC SHOCK can kill e Turn off machine at the disconnect switch on the front of the machine before tightening cleaning or replac ing consumables 1 Occasionally an oxide layer may form over the tip of the electrode creating an insulating barrier between the electrode and nozzle This will result in the tripping of the Pro Cut s safety circuit When this happens turn the power off remove the noz zle and electrode and use the electrode to rub against the inside bottom surface of the nozzle This will help remove any oxide buildup Replace the nozzle turn on the power and continue cutting If the Parts in Pla
109. inch pounds Replace the gas hose restraints previously removed Clear and reposition any leads that may be disturbed Replace the case wraparound cover Return to Section TOC Return to Master TOC PRO CUT 55 LINCOLN amp F 66 F 66 TROUBLESHOOTING amp REPAIR INPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT A WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manu al 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 test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION The following procedure will aid the technician in removing the input rectifier bridge for main tenance or replacement MATERIALS NEEDED 3 16 Allen type wrench Phillips head screw driver Torque wrench Penetrox A13 Lincoln E2529 Electrical Joint Compound Essex DC 4 8 Lincoln E3539 Electrical Insulating Compound Return to Section TOC Return to Master TOC O Fle g gt 018 5
110. ircuit on the output board then sends a signal to the control board LED5 Green This light indicates that the elec trode solenoid driver circuit is functioning When this light is lit the electrode solenoid should be activated The electrode solenoid should be energized during gas air pre flow time During pilot and cutting arc periods the LED should be off When the arc goes out the machine enters the post flow state Two seconds after the start of post flow the electrode solenoid is activated a few times The LED should blink to indicate this activity The electrode solenoid will then be energized for the duration of post flow The LED should be on Return to Section TOC Return to Master TOC PRO CUT 55 LINCOLN amp Return to Section TOC Return to Master TOC Return to Section TOC O Fle Cc gt 0218 5 4 x Return to Section TOC Return to Master TOC Return to Master TOC F 48 TROUBLESHOOTING amp REPAIR LOW VOLTAGE CIRCUIT TEST continued FIGURE F 14 CONTROL BOARD LEDs PRO CUT 55 CONTROL G3328 9 CONTROL BOARD LED DEFINITIONS LED1 Red This light indicates that 18 VAC is being supplied to the control board from the auxiliary transformer It also shows that the 18 VAC is being rectified and should be regulated to 15 VDC This 15 supply is used to power the circuitry on the control board LED2 Red This light indic
111. is recommended that consumables be replaced in complete sets Example Electrode and Nozzle This will maximize the performance of the Pro Cut 55 sys tem LIMITATIONS Do not exceed output current and duty cycle rating of machine Do not use the Pro Cut 55 for pipe thawing PRO CUT 55 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O Fle Cc gt 0218 5 4 x Return to Section TOC Return to Master TOC B 5 B 5 OPERATION CONTROLS AND SETTINGS FIGURE B 2 CASE FRONT CONTROLS OUTPUT CURRENT CONTROL KNOB TORCH CONNECTOR WORK CABLE INPUT POWER SWITCH GAS REGULATOR KNOB GAS REGULATOR GAUGE GAS PURGE BUTTON RESET BUTTON STATUS DISPLAY BOARD INDICATORS OUTPUT CURRENT CONTROL KNOB Agjusts the amount of cutting current applied Affects cut ting speed dross formation cut width heat zone and travel speed TORCH CONNECTOR Quick connect type cou pling for the PCT 80 cutting torch WORK CABLE Provides clamp and cable con nection to workpiece ON OFF POWER SWITCH Turns machine on or off GAS REGULATOR KNOB Adjusts compressed gas pressure delivered to the torch Length of torch hose is an adjustment factor Optimum set ting is 70 75 psi The gas purge button must be pressed in to set pressure GAS REGULATOR GAU
112. it Diagram oO cc 4 Check for the presence of approximately 28 7 Check for the presence of 15 VDC on the con VDC on the output board trol board a LED1 should be lit when 28 is present a LED3 should be lit when 15 VDC is pre See F 13 Output Board LED sent See Figure F 13 See Control Definitions and Figure F 12 Low Voltage Board LED Definitions and Figure F 12 Circuit Diagram Low Voltage Circuit Diagram b To verify the presence of 28 VDC check across capacitor C13 Make certain the voltmeter probes make good contact with the capacitor leads See Figure 13 Return to Section TOC Return to Master TOC PRO CUT 55 LINCOLN F 46 F 46 TROUBLESHOOTING amp REPAIR 8 Check for the presence of 5 VDC on the control board a LED2 should be lit when 5 VDC is pre sent See Figure F 14 See Control Board 9 Check for the presence of 15 VDC being applied to the display board from the control board You may have to remove the display board to check it Return to Section TOC Return to Master TOC a 15 VDC should be present at leads 216 to 219 See Figure F 15 and 10 If any of the DC supply voltages are incorrect or missing make certain the correct AC sup ply voltages are being applied to the P C boards See and 11 When the test is complete remove input power and replace the case wraparound cover Return to Section TOC Return to Master TOC
113. lace damaged insulation Never dip the torch in water for cooling or plasma cut or gouge in or under water When working above floor level protect yourself from a fall should you get a shock 1 i Operate the pilot arc with caution The pilot arc is capable of burning the operator others or even piercing safety clothing 1 j Also see Items 4c and 6 2 b 2 C ARC RAYS can burn 2 a Use safety glasses and a shield with the prop er filter and cover plates to protect your eyes from sparks and the rays of the arc when performing or observing plasma arc cutting or gouging Glasses headshield and filter lens should conform to ANSI Z87 standards Use suitable clothing including gloves 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 OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE FUMES AND GASES can be dangerous 3 a Plasma cutting or gouging may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When cutting or gouging keep your head out of the fumes Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When cut
114. le When the trigger is pulled air flow begins and creates enough back force on the electrode to overcome the force of the spring However the solenoid valve allows enough forward force on the piston to maintain continu ity between the consumables After this continuity has been verified by the Pro Cut s parts in place circuit out put current is established and regulated Once the cur rent stabilizes the solenoid valve turns off removing the forward force on the piston The back pressure drives the piston and electrode away from the nozzle creating the plasma arc The air stream forces the arc out the ori fice of the nozzle This appears as a pilot arc which can then be transferred for cutting PRO CUT 55 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O Cc gt 2 5 4 x Return to Section TOC Return to Master TOC E 6 E 6 THEORY OF OPERATION FIGURE E 6 CONTROL AND DISPLAY BOARDS POWER BOARD INPUT LINE INPUT SWITCH RECTIFIER 0 COomzzoormzgz AIR PRESSURE SWITCH zo d4om Jdozvu SIGNAL 18 36VAC THERMOSTATS FAN MOTORS AUX AH Y TRANSFORMER CONTROL AND DISPLAY BOARDS The control board receives status and analog feed back signals from the output board display board power board and various sensors The processor interprets the
115. lectric 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 LINCOLN ine LINCOLN 9 meee PROCUT 55 9 F3 UJ ii ss m A A z 2 1 2 1 214 2 Return to Section TOC Return to Master TOC Return to Section TOC Return to Section TOC O Fle C Ix gt 0218 5 4 cc Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC G 13 PC BOARD ASSEMBLY POWER G3172 2 ELECTRICAL DIAGRAMS ITEM REQ D PART NO IDENTIFICATION CI SES EB CI 4 S 16668 6 4700pF 50 Db tg E 4 520500 4 0047 1000V 2 16668 5 4022 50 3 5 16668 9 150pF 100 2 S 13490 93 27 35 1 S 13490 130 527790 1 13490 83 50 25V 16 019 2 13490 42 1 0 39 1 S 13490 39 18 15 ________________ ___ 514293 18 DPST RELAY 1 D2 D3 D4 05 D6 D 7 D12 I3 12199 1 1 4004 013 014 015 016 017 US D9 910 4 12705 44 DIODE 1000V 1A 071 825 029 0212 4 12702 40 1N4735 022 075 026 027 020 DZ 10 1 4744 0211 0213 0214 074 0215 2 112702 19 1447424
116. mal LED will light and the thermostat will prevent output voltage or current Thermostats are self resetting once the machine cools sufficiently If the thermostat shutdown was caused by excessive output or duty cycle and the fan is operat ing normally the Power Switch may be left on and the reset should occur within a 15 minute period If the fan is not turning or the air intake louvers were obstructed then the power must be switched off and the fan prob lem or air obstruction must be corrected 2 Filter Capacitor Conditioning Pro Cut 55 400 460 VAC only A protection circuit is included to monitor the voltage across filter capacitors C1 and C2 In the event that the capacitor voltage is too high the protection circuit will prevent output The protection circuit may prevent output providing all these circumstances are met a Machine is connected for 400 460 VAC input b Machine did not have power applied for many months c Machine will not produce output when power is first switched on If these circumstances apply the proper action is to switch the machine on and let it idle for up to 30 min utes This is required to condition the filter capacitors after an extended storage time The protection circuit will automatically reset once the capacitor condition ing and resultant voltage levels are acceptable It may be necessary to turn the power switch off and back on again after this period PRO CUT 55 LINCOLN amp
117. mes from breathing zone CUTTING SPARKS can cause fire or explosion Keep flammable material away e Do not cut containers that have held combustibles ARC RAYS can burn 2 Wear eye ear and body protection PLASMA ARC can injure V e Keep your body away from nozzle and plasma arc e Operate the pilot arc with caution The pilot arc is capable of burning the oper ator others or even piercing safety clothing Observe additional Safety Guidelines detailed in the beginning of this manual PRO CUT 55 LINCOLN amp Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o gt 0218 5 4 x Return to Section TOC Return to Master TOC B 3 B 3 OPERATION GENERAL DESCRIPTION The Pro Cut 55 is an inverter based constant current continuous control plasma cutting power source It provides superior and reliable starting characteristics cutting visibility and arc stability When cutting expanded metal the Pro Cut 55 out performs the competition due to its quick clean response to arc transfers The power supply design provides high transfer to cut distances which makes pierce cutting more reliable with less nozzle wear The control system has a safety mechanism to insure that the nozzle and electrode are in place before cutting or gouging This is extremely important due to the high voltages i
118. ng on equipment Do not touch electrically hot parts e Prior to performing preventative maintenance per form the following capacitor discharge procedure to avoid electric shock INPUT FILTER CAPACITOR DISCHARGE PROCEDURE 1 Turn off input power or disconnect input power lines 2 Remove the 5 16 in hex head screws from the side and top of the machine and remove wrap around machine cover 3 Be careful not to make contact with the capacitor terminals that are located on the top and bottom of the Power Board on the right side of the machine Obtain a high resistance and high wattage resistor 25 1000 ohms and 25 watts minimum This resis tor is not supplied with machine NEVER USE A SHORTING STRAP FOR THIS PROCEDURE Locate the two capacitor terminals large hex head cap screws on the top and bottom of the Power Board shown in Figure D 1 Use electrically insulated gloves and insulated pli ers Hold the body of the resistor and connect resistor leads across the two capacitor terminals Hold the resistor in place for 10 seconds DO NOT TOUCH CAPACITOR TERMINALS WITH YOUR BARE HANDS Repeat the discharge procedure for the other capacitor Check voltage across the terminals of all capaci tors with a DC voltmeter Polarity of capacitor ter minals is marked on the Power Board above termi nals Voltage should be zero any voltage remains repeat this capacitor discharge proce dure FIGUR
119. nsulator pro vides an electrical barrier between the piston and torch body The piston provides a path for electrical current to the electrode The piston also drives the electrode to the nozzle for arc initiation The torch body contains the main torch components the trigger pilot arc cutting arc and air flow systems are included CONTROL BOARD ELECTRODE SOLENOID ENABLE AIR SOLENOID ENABLE DISPLAY BOARD lt mI Sor gt r2EXmra lt gt B E FIGURE E 5 PLASMA OUTPUT BOARD AND TORCH WORK o g Y NOZZLE 2 i z POWER BOARD c OUTPUT BOARD c 2 TRIGGER amp SAFETY AIR OLENOID ELECTRODE amp TRANSFER CURRENT FEEDBACK PILOT ENABLE A copper nozzle with a patented internal swirl is used to focus the arc A small precise hole in the end of the noz zle constricts the arc and increases the current density As the air enters the torch head it is directed between the electrode and nozzle for maximum electrode cooling A portion of the cooling air exits the chamber through vents in the side of the nozzle A swirl texture located inside the bottom of the nozzle increases the plenum air swirl strength and improves arc start reliability and parts in place verification Plasma arc initiation occurs as follows First in the idle state a spring inside the torch head pushes the piston and electrode forward to make continuity with the nozz
120. nu al 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 test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION This procedure will help the technician determine if the solenoid is functioning properly Return to Section TOC Return to Master TOC MATERIALS NEEDED 5 16 Nut driver 12 VDC Q 3 amp supply Volt ohmmeter O Fle g gt 018 5 Return to Section TOC Return to Master TOC PRO CUT 55 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC O Fle C gt 0218 5 cc Return to Section TOC Return to Master TOC Return to Master TOC F 33 F 33 TROUBLESHOOTING amp REPAIR AIR GAS SOLENOID TEST continued FIGURE 6 AIR SOLENOID TEST PROCEDURE Ti 2 input power to the machine Perform the Capacitor Discharge Procedure detailed earlier in this section Locate the air solenoid and leads See Figure F 6 Carefully remove plug J31 from the output power board See Figure F 7 Check the coil resistance of the solenoid at plug J31 pin 6 to J31 pin 5 Normal resis tance is approximately 20 ohms If the resis tance is
121. nvolved The Pro Cut 55 comes standard with an air regulator coarse air filter and pressure gauge The machine also comes with an 11 foot 3 35m input power cord There are four different torch and cable systems to choose from hand held torch with 25 foot 7 62m or 50 foot 15 24m cable machine and robotic torch both with 25 foot 7 62m and 50 foot 15 24m cable Consumables are included with each Pro Cut pur chase so that cutting can begin right out of the box Consumables can also be ordered as individual pack ages An undercarriage kit can be ordered separately The Pro Cut 55 initiates the plasma arc with a simple yet reliable touch start mechanism This system elim inates many of the failure problems associated with hi frequency start systems The Pro Cut 55 is capable of cutting with nitrogen or air The Pro Cut 55 is controlled by a microprocessor based control board The machine performs rudimen tary self troubleshooting when powered up which aids in field servicing RECOMMENDED PROCESSES AND EQUIPMENT The Pro Cut 55 is capable of all cutting and gouging applications within its output capacity of 25 to 55 amps These applications include thin gage sheet metal and expanded metal OPERATIONAL FEATURES AND CONTROLS The Pro Cut 55 comes with an ON OFF POWER SWITCH OUTPUT CURRENT CONTROL PURGE BUTTON STATUS INDICATORS and a SAFETY RESET BUTTON See Figure B 2 and related discus sion DESIGN FEATURES AN
122. ocessor control board The control system has a safety mech anism to insure that the nozzle and electrode are in place before cutting or gouging The Pro Cut 55 initi ates the plasma arc with a simple yet reliable touch start mechanism This system eliminates many of the problems associated with hi frequency type start sys tems DISPLAY BOARD WORK NOZZLE ELECTRODE TORCH OUTPUT BOARD MAIN TRANSFORMER I EI TRIGGER amp SAFETY AIR OLENOID 5 AIR B PRESSURE 51 SWITCH ii Ole E o gt ELECTRODE amp TRANSFER Q CURRENT FEEDBACK 9 5 SIE PILOT ENABLE CONTROL BOARD ELECTRODE SOLENOID ENABLE 5 5 AIR SOLENOID ENABLE io T a M cic R E F A R E W Y OUTPUT INPUT LINE VOLTAGE CONTACTOR AND MAIN TRANSFORMER The single phase or three phase input power of 200 230 or 400 to 460 volts AC is connected to the machine via an input line cord to a switch located on the front panel A reconnect panel and voltage range switch allow the user to configure the machine for either a low or high input voltage and also connect the auxiliary trans former for the appropriate input voltage The auxiliary transformer develops the appropriate AC voltages to operate the cooling fans the control board and the plasma output board NOTE Unshaded areas of Block Logic Diagram are the subject of discussi
123. on PRO CUT 55 LINCOLN E 3 E 3 THEORY OF OPERATION FIGURE E 3 PRECHARGE AND PROTECTION Return to Section TOC Return to Master TOC O Cc gt 2 5 4 x Return to Section TOC Return to Master TOC POWER BOARD ed rOd zo 2 CONTROL AUX AHY TRANSFORMER PRECHARGE AND PROTECTION The input voltage is rectified by the input rectifier The resultant DC voltage is applied through the reconnect switch to the power board The power board contains precharging circuitry for the safe charging of the input filter capacitors Once the capacitors are precharged and balanced the control board activates the CH1 input relay This connects full input power to the filter capacitors When the filter capacitors are fully charged they act as power supplies for the IGBT switching circuit The Insulated Gate Bipolar Tran sistors supply the main transformer primary winding with DC current flow See GBT Operation discussion and diagrams in this section LI DISPLAY BOARD WORK NOZZLE ELECTRODE TORCH OUTPUT BOARD CONNECTOR MAIN TRANSFORMER saxi sc dsl TRIGGER amp SAFETY AIR OLENOID Fir 5 D AIR R io PRESSURE SWITCH T 4 gt ELECTRODE amp TRANSFER Q CURRENT FEEDBACK Q Q PILOT ENABLE cic CONTROL BOARD ELECTRODE SOLENOID ENABLE 5 5 AIR SOLENOID ENABLE
124. orches come in 25 and 50 lengths in either hand held or mechanized versions ALWAYS USE GENUINE LINCOLN ELECTRIC ELECTRODES AND VORTECH NOZZLES e Only Genuine Lincoln Electric consumables yield the best cutting performance for the Pro Cut 55 e The patent pending VORTECH nozzle provides an extra kick of swirl as the arc exits the nozzle which improves cutting performance No other noz zle has this capability or can match its performance PRO CUT 55 LINCOLN amp Section D 1 Section D 1 TABLE OF CONTENTS MAINTENANCE 0 Section D C D 2 Input Filter Capacitor Discharge nnne D 2 Routine D 3 Return to Master TOC Periodic Maintenance 0 3 Return to Master O O 4 gt c 2 4 Return to Master PRO CUT 55 LINCOLN amp Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O Fle Cc gt 0218 5 4 x Return to Section TOC Return to Master TOC D 2 D 2 MAINTENANCE WARNING ELECTRIC SHOCK can kill e Have an electrician install and service this equipment e Turn the input power off at the fuse box before worki
125. put current exceeds 50 60 amps an electronic protection circuit limits the current to within the capabilities of the machine Another protection circuit monitors the voltage across the input filter capacitors If the filter capacitor voltage is too high too low or not balanced the protection cir cuit may prevent machine output THERMAL PROTECTION Two thermostats protect the machine from excessive operating temperatures One thermostat is located on the output choke and the other on the power board IGBT heat sink Excessive temperatures may be caused by a lack of cooling air or by operating the machine beyond the duty cycle and output rating excessive operating temperatures should occur the thermal status indicator will light and the thermostat Will prevent output voltage or current Thermostats are self resetting once the machine cools sufficiently If the thermostat shutdown was caused by excessive output or duty cycle and the fans are operating normally the power switch may be left on and the reset should occur within a 15 minute period If the fan or fans are not turning or the air intake lou vers are obstructed the input power must be removed and the fan problem or air obstruction must be cor rected PRO CUT 55 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O Fle Cc gt 0218 5 4 x Return to Section TOC
126. r multimeter PRO CUT 55 LINCOLN F 44 F 45 F 45 TROUBLESHOOTING amp REPAIR LOW VOLTAGE CIRCUIT TEST continued FIGURE F 12 LOW VOLTAGE CIRCUIT DIAGRAM TO H1 C TERMINAL RECTIFIER 12VAC Brown O O c 9 4 0 4 2 rm Return to Master N TO BLUE 4 1 18VAC 15VDC NS ASIE 8621221 CONTROL BOARD 9 9 N LBVAC Be Et Ec 0912 121 FEE 2 PROCEDURE 3 cle 1 Remove input power to the Pro Cut 55 5 Check for the presence of 17 VDC on the out 5 5 machine put board 2 2 Using the 5 16 nutdriver remove the case a LED2 should be lit when 17 VDC is present wraparound cover See Figure F 13 See Output Board LED and Figure F 12 Low Voltage A WARNING Circuit Diagram b To verify the presence of 17 VDC check ELECTRIC SHOCK can kill from plug J31 Pin 6 to diode D25 anode Do not touch electrically hot parts See Figure 13 Make certain the volt meter probes make good contact with pin E 6 and the diode anode lead E lg 6 Check for the presence of 15 VDC on the 2 control board E LED1 should be lit when 15 VDC is pre 2 2 sent See Figure F 13 See Control 3 Apply the correct input power to machine Board LED Definitions and Figure F 12 5 E and carefully check for the following voltages Low Voltage Circu
127. re missing or very low NOTE There should not be continuity between with the proper primary voltage applied the the isolated windings With the input auxiliary transformer may be faulty power removed from the transformer check the windings using the table 9 f the auxiliary transformer tests good but it below does not function when connected to the Pro Cut 55 check the harness wiring to the auxiliary transformer See the Wiring Diagram TEST POINT TEST POINT EXPECTED RESISTANCE Greater than 100 K ohms Red Lead Greater than 100 K ohms Brown Leads Brown Leads Red Leads PRO CUT 55 LINCOLN amp F 36 F 37 LINCOLN amp NOTES PRO CUT 55 F 37 NOL 491Se A 0 uunjeH 901 491Se A 0 uunjeH NOL J91Se AN 0 uunjeH NOL uunjeH DOL uonoes DOL uonoes uunjeg DOL DOL F 38 F 38 TROUBLESHOOTING amp REPAIR TRIGGER CIRCUIT TEST A WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manu al Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable
128. rform the Low Voltage reconnect panel S IIT Circuit Test 3 Perform the Input Rectifier 4 The control board may be faulty Replace 5 he display board may be faulty Replace All status indicators remain imme The microprocessor has experi 1 The control board may be diately after power up enced a memory fault Contact faulty Replace your Local Lincoln Authorized Field Service Facility CAUTION If for any reason you do not understand the test procedures are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 PRO CUT 55 LINCOLN amp Return to Section TOC Return to Master TOC Return to Section TOC O Fle gt 018 5 Return to Section TOC Return to Master TOC Return to Master TOC F 5 F 5 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS All the status lights begin to blink within 5 seconds of power up machine powers up properly but there is no response when the gun trigger is pulled Only the power LED is lit When the torch trigger is pulled air begins to flow but no pilot arc is established Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S 1 2 1 A 3 1 2
129. rical noise to trip the safety circuit on rare occasions This should not be a regular occurrence e f the machine does not reset or continues to trip consult the Troubleshooting Section e Use the proper cutting or gouging procedures referred to in Procedure Recommendations below USER RESPONSIBILITY Because design fabrication erection and cutting vari ables affect results the serviceability of a product or structure is the responsibility of the user Variation such as plate chemistry plate surface condition oil scale plate thickness preheat quench gas type gas flow rate and equipment may produce results different from those expected Some adjustments to proce dures may be necessary to compensate for unique individual conditions Test all procedures duplicating actual field conditions PREHEAT TEMPERATURE FOR PLASMA CUTTING Preheat temperature control is not necessary in most applications when plasma arc cutting or gouging Preheat temperature control may be necessary on high carbon alloy steels and heat treated aluminum for crack resistance and hardness control Job condi tions prevailing codes alloy level and other consider ations may also require preheat temperature control The recommended minimum preheat temperature for plate thickness up to 1 2 in 12 7mm is 70 F 21 1 C Higher temperatures may be used as required by the job conditions and or prevailing codes If cracking or excessive hardnes
130. ro Cut 55 gas inlet PRO CUT 55 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC O Fle Cc gt 0218 5 4 cc Return to Section TOC Return to Master TOC Return to Master TOC A 8 A 8 INSTALLATION OUTPUT CONNECTIONS FIGURE A 4 TORCH CONNECTION AT CASE FRONT TORCH CONNECTION The Pro Cut 55 is supplied from the factory with a PCT 80 cutting torch Additional cutting torches can be ordered from the K1571 series Hand held and mech anized torches come with 25 or 50 foot cables All torches are connected to the Pro Cut with a quick connect at the case front for easy change over See Figure A 4 PRO CUT55 For more information on the torch and its components refer to the PCT 80 Operators Manual IM588 1 TORCH CONNECTION PRO CUT 55 LINCOLN Section B 1 Section B 1 TABLE OF CONTENTS E OPERATION SECTION gt SF 6 Section B DAISY 2 B 2 8 Tm B 3 Recommended Process and B 3 E Operational Features and Controls B 3 Design Features and nnns B 3 CUMING 9 TL B 4 COn umane L B 4 NEED ETE B 4 T
131. rom the machine PRO CUT 55 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O Fle Cc gt 0218 5 4 x 26 26 TROUBLESHOOTING 8 REPAIR OUTPUT POWER BOARD RESISTANCE TEST continued TABLE F 4 OUTPUT POWER BOARD RESISTANCE TEST POINTS Probe J33 Pin4 to Probe Terminal B11 Probe Terminal B11 to Probe J33 Pin4 J33 Pin4 to Probe Terminal B12 Probe Terminal B12 to Probe J33 Pin4 or D30 Probe R5 Test Point to Probe Terminal B1 Probe Terminal B1 to Probe R5 Test Point Or Probe D30 Test Point or D30 Probe 5 Test Point to Probe Terminal B2 Probe Terminal B2 to Probe R5 Test Point Or Probe D30 Test Point Probe R5 Test Point to Probe J32 Pin14 Probe J32 Pin14 to Probe i Point Probe D30 Test Point CIRCUIT OR COMPONENT S BEING TESTED Diode A1 and associated trace Diode A1 and associated trace Diode A1 and associated trace Diode A1 and associated trace Diode A2 and associated trace Diode A2 and associated trace Diode A2 and associated trace Diode A2 and associated trace Transistor A2 and associated trace Transistor A2 and associated trace If any of the resistance checks are not correct the output power board is faulty Replace See the Outp
132. ry 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 malfunc tions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symp toms that the machine may exhibit Find the list ing that best describes the symptom that the machine is exhibiting Symptoms are grouped into four main categories Output Problems Function Problems Cutting Problems and LED Function Problems Step 2 PERFORM EXTERNAL TESTS The second column labeled POSSIBLE AREAS OF MISADJUSTMENT S lists the obvious external possibilities that may contribute to the machine symptom Perform these tests checks in the order listed In general these tests can be con ducted without removing the case wrap around cover Step 3 PERFORM COMPONENT TESTS The last column labeled Recommended Course of Action lists the most likely components that may have failed in your machine It also specifies the appropriate test procedure to verify that the sub ject component is either good or bad If there are a number of possible components check the components in the order listed to eliminate one possibility at a time until you locate the cause of your problem All of the referenced test
133. s light indicates that 24 VAC is being supplied to the output board from the aux transformer It also shows that the 24 is being rectified to approximately 28 VDC This DC voltage is used for the parts in place check for the torch circuit LED2 Red This light indicates that 12 VAC is being supplied to the output board from the aux transformer It also shows that the 12 VAC is being rectified to approximately 17 VDC This DC voltage is used to power the trigger circuit and solenoid driver circuits incorporated on the output board LEDS Green This light indicates that the air solenoid driver circuit is functioning When this LED is lit the air solenoid should be activated G3326 2 3 LED4 Green This light indicates that the trig ger circuit on the output board has been activat ed This LED should be lit when the torch or remote trigger is closed This trigger circuit on the output board then sends a signal to the control board LED5 Green This light indicates that the elec trode solenoid driver circuit is functioning When this light is lit the electrode solenoid should be activated The electrode solenoid should be energized during gas air pre flow time During pilot and cutting arc periods the LED should be off When the arc goes out the machine enters the post flow state Two seconds after the start of post flow the electrode solenoid is activated a few times The LED should blink
134. s occurs on the cut face higher pre heat temperature may be required PROCEDURE RECOMMENDATIONS When properly used plasma arc cutting or gouging is a very economical process Improper use will result in a very high operating cost GENERAL IN ALL CASES e Follow safety precautions as printed throughout this manual and on the machine THIN GAUGE SHEET METAL Torch Standoff Machine Output Setting DRAG thru 1 16 Standoff Output Setting Min thru Mid Range Output set below mid range e The nozzle may be dragged on the metal surface touching it lightly to the surface after piercing a hole Current control should be set below the mid range e Do not allow cable or body to contact hot surface PRO CUT 55 LINCOLN amp Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O Fle Cc gt 0218 5 4 x Return to Section TOC Return to Master TOC B 8 B 8 OPERATION THICK SECTIONS OF METAL Torch Standoff Machine Output Setting 1 8 thru 3 16 Standoff Output Setting Mid thru Max Range Output set above mid range he best quality and consumable life will be obtained by holding the torch off the surface about 3 16 in 4 7mm Too long an arc may compromise cut quality and consumable life The nozzle should NOT be dragged on the work Use of the 22151 Drag Cup w
135. se signals makes decisions and changes machine mode and output to satisfy the requirements as defined by the internal software The control board WORK ELECTRODE NOZZLE MAIN TRANSFORMER OUTPUT BOARD poc 1 TORCH al CONNECTOR TRIGGER amp SAFETY AIR OLENOID ELECTRODE amp TRANSFER CURRENT FEEDBACK PILOT ENABLE ELECTRODE SOLENOID ENABLE AIR SOLENOID ENABLE x mm o0 regulates the output of the machine by controlling the IGBT switching times through pulse width modulation circuitry See Pulse Width Modulation in this section The display board receives commands from the con trol board and via indicator lights communicates Pro Cut 55 status and operating conditions to the user PRO CUT 55 LINCOLN amp Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O O 0 4 c 2 4 Return to Section TOC Return to Master TOC O O 4 gt c 2 4 THEORY OF OPERATION PROTECTION CIRCUITS Protection circuits are designed into the Pro Cut 55 machine to sense trouble and shut down the machine before the trouble damages internal machine compo nents Both overload and thermal protection circuits are included OVERLOAD PROTECTION The Pro Cut 55 is electrically protected from produc ing higher than normal output currents If the out
136. st locations on the primary power board See Figure PRO CUT 55 LINCOLN 4 The following tests will be performed with the input power applied to the Pro Cut 55 BE CAREFUL ALWAYS REMOVE THE INPUT POWER AND PERFORM THE INPUT FILTER CAPACITOR DISCHARGE PROCEDURE BEFORE TOUCHING ANY MACHINE COMPONENT A WARNING ELECTRIC SHOCK can kill e Have an electrician install and service this equipment e Turn the input power off at the fuse box before working on equipment Do not touch electrically hot parts 5 Apply the correct input powert and turn ON the Pro Cut 55 T NOTE This test should only be conducted with the Pro Cut 55 reconnect switch and A jumper configured for 400 VAC and above F 22 F 22 TROUBLESHOOTING amp REPAIR PRIMARY POWER BOARD RESISTANCE TEST AND CAPACITOR VOLTAGE TEST continued 6 Check for the appropriate voltages outlined 7 the test voltages do not meet the expect in Table ed values as listed in Table F 3 the capaci tors or other components on the power NOTE Voltages may vary with the input line board may be faulty Replace voltage Return to Section TOC Return to Master TOC NOTE If the capacitor voltages are NOT bal anced within 20 VDC the capacitors may need conditioning See the Maintenance section NOTE If the capacitor voltage is too high over 400 VDC or too low less than 220 VDO the control board will deactivate relay CR
137. such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when cutting or goug ing out of position or in confined places Always wear safety glasses with side shields when in a cutting or gouging area 4 h Connect the work cable to the work as close to the cutting or 5 b 5 f 5 0 gouging area as practical Work cables connected to the build ing framework or other locations away from the cutting or goug ing area increase the possibility of the current passing through lifting chains crane cables or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail CYLINDER may explode if damaged 5 a Use only compressed gas cylinders contain ing the correct gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition 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 plasma cutting or gouging arc weld ing operations and any other source of heat sparks or flame Never allow any part of the electrode torch or any other elec trically hot parts to touch a cylinder Keep your he
138. t B 5 e LAE __ B 5 5 e B 5 O E B 7 m Preheat Temperature for Plasma Cutting esses nnne nnns B 7 z Procedure Recommendati ns nieni arrr eni HDI DENN n DERE arisia B 7 EE Kc ERE TN URS B 7 Thin Gauge Sheet Metal e B 7 THICK SECUONS OF 122 B 8 Suggestions for Extra Utility From the Pro Cut B 8 v g c D v c PRO CUT 55 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC O Fle Cc gt 0218 5 4 x Return to Section TOC Return to Master TOC Return to Master TOC B 2 OPERATION ide OPERATING INSTRUCTIONS Read and understand this entire section of operating instructions before operating the machine SAFETY INSTRUCTIONS A WARNING e ELECTRIC SHOCK can kill Do not touch electrically live parts or electrodes with your skin or wet cloth ing e Insulate yourself from the work and ground e Always wear dry insulating gloves FUMES AND GASES can be dangerous e Keep your head out of fumes AD e Use ventilation or exhaust to remove fu
139. test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 PRO CUT 55 LINCOLN amp Return to Section TOC Return to Master TOC Return to Section TOC O Fle gt 018 5 Return to Section TOC Return to Master TOC Return to Master TOC F 8 F 8 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS The Air Low LED is lit The Safety LED is flashing The Safety LED is lit and ready POSSIBLE AREAS OF MISADJUSTMENT S LED FUNCTION PROBLEMS Make sure there is at least 70 psi 448 kPa of air pressure connected to the gas connec tion at the back of the Pro Cut 55 Press the purge button and set the regulator to 70 psi 448 kPa Do not reset the air pres sure while the air is off not flow ing Make sure there is a Lincoln PCT 80 torch connected prop erly to the Pro Cut 55 Make sure the torch consum ables are in place and in good condition Press the reset button f the torch and consumables are properly installed the Safety LED should turn off TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION The pressure switch S5 or associated leads may be faulty See the Wiring Diagram
140. them until installation is complete If you return a PC board to The Lincoln Electric Company for credit it must be in the static shielding bag This will prevent further damage and allow prop er 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 troubleshooting NOTE Allow the machine to heat up so that all electrical components can reach their operating temperature 5 Remove the replacement PC board and substitute it with the original PC board to recreate the original problem a If the original problem does not reappear by substituting the original board then the PC board was not the problem Continue to look for bad connections in the control wiring harness junction blocks and terminal strips b If the original problem is recreated by the substitution of the original board then the PC board was the problem Reinstall the replacement PC board and test the machine 6 Always indicate that this procedure was followed when warranty reports are to be submitted NOTE Following this procedure and writing on the warranty report INSTALLED AND SWITCHED PC BOARDS TO VERIFY PROBLEM will help avoid denial of legitimate PC board warranty claims PRO CUT 55 LINCOLN amp Return to Section TOC Return to Master TOC Return to Section TOC O
141. ting or gouging on lead or cadmium plat ed 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 Do not use plasma arc cutting or gouging 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 3 c Gases used for plasma cutting and gouging can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe 3 d Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employ er s safety practices CUTTING SPARKS can cause fire or explosion 4 a Remove fire hazards from the plasma cutting or gouging area If this is not possible cover them to prevent the cutting or gouging sparks from starting a fire Remember that welding sparks and hot materials from plasma cutting or gouging can easily go through small cracks and openings to adjacent areas Avoid cutting or gouging ne
142. tion TOC Return to Master TOC Return to Section TOC O Fle gt 018 5 Return to Section TOC Return to Master TOC Return to Master TOC F 7 F 7 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS The pilot arc is normal but the arc will not transfer to the workpiece Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S CUTTING PROBLEMS Make sure the operating proce dure is correct for the process See the Operation section of this manual Make sure the work clamp is connected tightly to the work piece The workpiece must be electri cally conductive material Check RECOMMENDED COURSE OF ACTION Check the lead connections X2 X4 and B21 at the output board the output control potentiometer R1 Normal resistance is 10 ohms Also check the associated leads for loose or faulty connections to the display board See the Wiring Diagram Check leads 216 4218 and 4219 between the display board and the control board Check for loose or faulty con nections See the Wiring Diagram The control board may be faulty Replace The output board may be faulty Perform the Output Board Resistance Test The display board may be faulty Replace CAUTION If for any reason you do not understand the
143. tput power board O Fle C Ix gt 018 5 4 t cc 8 Using 3 16 allen head wrench remove the four socket screws mounting the output power board to the heat sink Return to Section TOC Return to Master TOC PRO CUT 55 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC O Fle Cc gt 0218 5 4 x Return to Section TOC Return to Master TOC Return to Master TOC F 61 TROUBLESHOOTING amp REPAIR OUTPUT POWER BOARD REMOVAL amp REPLACEMENT continued REPLACEMENT PROCEDURE 1 Apply a thin coating of Penetrox A 13 Electrical Joint Compound to the mating sur faces of the output power board and the heat sink Make sure the surfaces are clean Do not allow the compound to get into the threaded holes or on the screw threads A CAUTION Be sure to follow the recommended static free methods for handling printed circuit boards railure to can resuitin permanent damage to the equipment 2 Mount the output power board to the heat sink and pre torque the four socket head screws to 25 inch pounds 3 Finish tightening the four screws to 40 48 inch pounds 4 Replace the two phillips head screws previ ously removed Replace leads X20 and X40 Replace all plugs previously removed Replace leads X4 and X2 p Replace lead B21 and torque it to 70 inch poun
144. unjeH 901 491Se N 01 uunjeH NOL J91Se AN 0 uunjeH NOL uunjeH DOL uonoes uunjeg DOL uonoes uunjeg DOL DOL Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O Fle g gt 018 5 Return to Section TOC Return to Master TOC F 44 TROUBLESHOOTING amp REPAIR LOW VOLTAGE CIRCUIT TEST A WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manu al If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION These voltage checks will help the technician determine if the correct voltages are being applied and processed by the various P C boards Some of the voltage verification test points are not easily accessible The presence of these voltages can also be confirmed by LEDs on the various P C boards MATERIALS NEEDED 5 16 Nut driver Volt ohmmete
145. urn to Master TOC O Fle g gt 018 5 Return to Section TOC Return to Master TOC F 12 TROUBLESHOOTING amp REPAIR INPUT FILTER CAPACITOR DISCHARGE PROCEDURE WARNING Service and repair should be performed by only Lincoln Electric factory trained person nel Unauthorized repairs performed on this equipment may result in danger to the tech nician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION This procedure will drain off any charge stored in the two large capacitors that are part of the power board assembly This procedure MUST be performed as a safety precau tion before conducting any test or repair procedure that requires you to touch internal components of the machine MATERIALS NEEDED Volt Ohmmeter Multimeter 5 16 Nut driver Insulated gloves Insulated pliers High wattage resistor 25 to 1000 ohms 25 watts minimum PRO CUT 55 LINCOLN amp F 12 Return to Section TOC Return to Master TOC Return to Section TOC O Fle Cc
146. urn to Master TOC F 18 TROUBLESHOOTING amp REPAIR PRIMARY POWER BOARD RESISTANCE TEST AND CAPACITOR VOLTAGE TEST A WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manu al If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION This test will determine if the primary power board has any shorted or leaky power diodes or Insulated Gate Bipolar Transistors IGBTs Also it will help to indicate any shorted input filter capacitors MATERIALS NEEDED Analog voltmeter ohmmeter multimeter Wiring Diagram 7 16 Wrench PRO CUT 55 LINCOLN F 18 TROUBLESHOOTING amp REPAIR PRIMARY POWER BOARD RESISTANCE TEST AND CAPACITOR VOLTAGE TEST continued FIGURE F 3 PRIMARY POWER BOARD REMOVAL Return to Section TOC Return to Master TOC CAPACITOR C2 TERMINALS 207 202 e A 201 PRIMARY POWER BOARD WITH INPUT FILTER CAPACITORS PRO CUT POWER G317
147. urn to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION This procedure will help the technician determine if the torch cable consumables and elec trode solenoid are functioning properly Return to Section TOC Return to Master TOC MATERIALS NEEDED 5 16 Nut driver Volt ohmmeter 12 VDC Q 1 Amp Power Supply O Fle g gt 018 5 Return to Section TOC Return to Master TOC PRO CUT 55 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O Fle Cc gt 0218 5 4 x Return to Section TOC Return to Master TOC F 29 F 29 TROUBLESHOOTING amp REPAIR TORCH CONTINUITY AND SOLENOID TEST continued FIGURE F 5 TORCH CONNECTOR MACHINE END White Pair Electrode Lead Not used inside mer powe r pilot path air tube crimp source Air Hose qing Red Leads N O Torch Trigger TEST PROCEDURE 3 Using the ohmmeter check the torch resis tances per Table 5 1 Remove input power to the Pro Cut 55 machine NOTE Take the Pin test point measurements at the machine end of the torch assem 2 Remove the torch assembly
148. ut Power Board Removal and Replacement EXPECTED RESISTANCE Less than 100 ohms Greater than 1000 ohms Less than 100 ohms Greater than 1000 ohms Less than 100 ohms Greater than 1000 ohms Less than 100 ohms Greater than 1000 ohms Less than 100 ohms Greater than 1000 ohms test the power diode and transistor portion of the board is good However other circuits on the power board may be faulty These circuits are NOT readily tested or serviceable Note Use 030 test point for boards Return to Section TOC Return to Master TOC 8 Reconnect the leads and plugs previously 7 the output power board passes the resistance removed PRO CUT 55 LINCOLN F 27 LINCOLN amp NOTES PRO CUT 55 F 27 NOL 491Se A 0 uunjeH 901 491Se A 0 uunjeH NOL J91Se AN 0 uunjeH NOL uunjeH DOL uonoes DOL uonoes uunjeg DOL DOL F 28 F 28 TROUBLESHOOTING amp REPAIR TORCH CONTINUITY AND SOLENOID TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manu al Return to Section TOC Ret
149. utting applications based on U S National Electrical Code Ambient Temperature 30 C or Less AC Input Voltage Fuse Super Lag Type 75 C at Circuit Breaker Copper Wire in Conduit AWG 60 Hertz Delay Type IEC Sizes 2 Input Supply Wires 1 Ground Wire 230VAC Single Phase 70 Amps 8 8 4mm 10 5 3mm 460VAC Single Phase 40 Amps 8 8 4mm 10 3mm 230VAC Three Phase 40 Amps 10 5 3mm 10 5 3mm 460VAC Three Phase 20 Amps 10 5 3mm 10 5 3mm PHYSICAL DIMENSIONS Height Width Depth Weight with Torch Cable 12 6 Inches 11 0 Inches 26 0 Inches 70 Ibs 32 kg 320 mm 280 mm 660 mm 25 ft cable 85 Ibs 39 kg 50 ft cable PRO CUT 55 LINCOLN 8 A 3 Return to Section TOC Return to Master TOC Return to Section TOC O Fle Cc gt 0218 5 4 x Return to Section TOC Return to Master TOC Return to Master TOC 4 4 INSTALLATION Read this entire installation section before you start installation SAFETY PRECAUTIONS WARNING e ELECTRIC SHOCK can kill Turn the input power OFF at the disconnect switch or fuse box and discharge input capacitors before working inside the equip ment Do not touch electrically hot parts or electrodes with your skin or wet clothing e Always connect the 55 grounding terminal located on the side of the Case Back Assembly to a good electrical earth ground e Alw
150. vel troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the LINCOLN machine ELECTRIC PROCUT 55 a ELECTRICAL DIAGRAMS G 10 SO OOO ev IS S O WEM RoD PART NO IDENTIFICATION _______ 82 T 13157 14 TAB TERMI NAL Oo C1 C3 C4 C11 215 C26 6 520500 5 0015200 C20 C22 C23 C24 4 5166685 022 50 LS L05 06 07 08 09 D2 03 04 05 D6 07 08 09 1 010 011 013 014 0 15 016 017 019 020 021 023 025 026 D 12 022 2 112705 34 1 4936 2 pue DZ 1 072 DZ4 075 026 T 12702 29 T 12702 19 1447424 518248 14 HEADER Ju eee LED3 LED4 205 T13657 3 GREEN LED pomum OCI 1 S 15000 26 OPTOCOUPLER LOGI C OUT 0 2 0 1 3 OCI 4 S 15000 10 ISOLATOR 01 03 12704 73 PKG MOSFET SS pu pe RI R37 R36 R39 4 714491 160 10 1 1 519400 4752 47 5K aw R8 10 R11 R12 R24 R26 R28 519400 1211 l 21K 1 4 R3 1 R32 840 R4 1 845 R46
151. y and higher quality cuts e Unique drag cup design for durability and elimina tion of double arcing PRO CUT 55 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC O Fle Cc gt 0218 5 4 x Return to Section TOC Return to Master TOC Return to Master TOC B 4 B 4 OPERATION CUTTING CAPABILITY The Pro Cut 55 is rated at 55 amps at 50 duty cycle on a 10 minute basis or 40 amps at 100 duty cycle If the duty cycle is exceeded a thermal protector will shut off the output of the machine until it cools to the normal operating temperature Figure B 1 shows the cut capacity of the Pro Cut 55 when cutting mild steel The graph plots cut thickness vs torch travel speed with a torch standoff of 0 15 in 3 8mm Example 0 25 material Amps Speed IPM 35 38 45 57 55 62 FIGURE B 1 LINCOLN S PRO CUT 55 MILD STEEL CUT CAPACITY CHART 100 Recommended Torch Travel Speed IPM 8096 of Maximum Speed 0 000 0 125 0 250 0 375 0 500 Material Thickness CONSUMABLE LIFE The expected life for the Pro Cut 55 s electrode under normal operating conditions is approximately 320 starts cuts An erosion of 060 in 1 5mm is typical for end of electrode life However the electrode may last longer A green and erratic arc will indicate definite electrode failure and the electrode should be replaced immediately It
152. you proceed Call 1 888 935 3877 DESCRIPTION This test will help determine if the input rectifier has shorted or open diodes MATERIALS NEEDED Analog voltmeter ohmmeter multimeter Phillips head screw driver Wiring diagram PRO CUT 55 LINCOLN F 14 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O Fle Cc xXx gt 3 5 4 x Return to Section TOC Return to Master TOC F 15 F 15 TROUBLESHOOTING amp REPAIR INPUT RECTIFIER TEST continued TEST PROCEDURE 1 Remove main input power to the machine 2 Perform the Filter Capacitor Discharge Procedure detailed earlier in this section 3 Locate the input rectifier D1 and lead loca tions See Figure F2 4 With the phillips head screw driver remove leads 207 207A and 209 from the rectifi er Use the analog ohmmeter to perform the tests detailed in Table F 1 See the Wiring Diagram FIGURE F 2 INPUT RECTIFIER AND LEADS PRO CUT 55 LINCOLN 207 207 F 16 F 16 TROUBLESHOOTING amp REPAIR Olio o INPUT RECTIFIER TEST continued 5 9 3 TABLE F 1 INPUT RECTIFIER TEST POINTS N 8 pe TEST POINT TERMINALS ANALOG METER X10 RANGE Acceptable Meter Readings 207 Greater than 1000 ohms 207 Greater than 1000 ohms Greater than 10
153. ype plugs in their respective receptacles Be certain they are securely in place Carefully reposition the front assembly in place and install the four mounting screws previously removed Inspect clear and secure all leads before installing the case wrap around reassembly Using the 5 16 nut driver install the case wraparound F 53 o D LLI 5 E TE co O LL NOL 491Se A 0 uunjeH NOL 491Se A 0 uunjeH NOL J91Se AN 0 uunjeH NOL uunjeH DOL uonoes DOL uonoes uunjeg DOL DOL Return to Section TOC Return to Master TOC Return to Section TOC O Fle g gt 018 5 Return to Section TOC Return to Master TOC Return to Master TOC F 54 TROUBLESHOOTING amp REPAIR DISPLAY BOARD REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manu al If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electric

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