Lincoln Electric SVM146-A - Manuals

Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC SAFETY iv iv PRO-CUT 80 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques qui parraissent dans cemanuel aussi bien que les précaut...

MASTER TABLE OF CONTENTS FOR ALL SECTIONS v v PRO-CUT 80 Page Safety .................................................................................................................................................i-iv Installation .......................................................................

Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TABLE OF CONTENTS - INSTALLATION SECTION - Section A-1 Section A-1 PRO-CUT 80 Installation Technical Specifications ...................................................................................................

Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC INSTALLATION A-2 A-2 PRO-CUT 80 TECHNICAL SPECIFICATIONS - PRO-CUT 80 INPUT RATINGS Single Phase Input Input Currents Ra...

Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC INSTALLATION A-3 A-3 PRO-CUT 80 TECHNICAL SPECIFICATIONS (Cont’d) - PRO-CUT 80 GAS REQUIREMENTS Required Gas Flow Rate R...

Read this entire installation section before youstart installation. SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Turn the input power OFF at the disconnect switch or fuse boxand discharge input capacitorsbefore working inside the equip-ment. • Do not touch electrically hot parts or electrodes with ...

INPUT CONNECTIONS ELECTRIC SHOCK can kill. • Have a qualified electrician install and service this equipment. • Turn the input power off at the fuse box before working on this equipment. • Do not touch electrically hot parts. Before installing the machine, check that input supplyvoltage, phase, and ...

RECONNECT PROCEDURE When received directly from the factory, the machinesare internally connected for 230 VAC. Reconnectionwill be necessary if a higher input voltage is used. Toreconnect the Pro-Cut to 460 VAC or to connect backto 230 VAC, follow the directions as outlined below.Follow this procedu...

Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC INSTALLATION A-7 A-7 PRO-CUT 80 GAS INPUT CONNECTIONS Supply the PRO-CUT 80 with clean compressed air ornitrogen. • Supp...

XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX PRO-CUT 80 TorchConnector WorkCable InputPowerSwitch OutputControlKnob ConsumableStorage(behinddoor) StatusIndicators ResetButton GasPurgeButton GasRegulatorGauge GasRegulatorKnob InterfaceConnector OUTPUT CONNECTIONS TORCH CONNECTION The PRO-CUT 80 is supplie...

Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Section B-1 Section B-1 PRO-CUT 80 TABLE OF CONTENTS - OPERATION SECTION - Operation ..................................................................................................................................

Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC B-2 B-2 PRO-CUT 80 OPERATING INSTRUCTIONS Read and understand this entire section of operatinginstructions before operat...

GENERAL DESCRIPTION The PRO-CUT 80 is an inverter based constant cur-rent, continuous control plasma cutting power source.It provides superior and reliable starting characteris-tics, cutting visibility and arc stability. When cuttingexpanded metal, the PRO-CUT 80 out-performs thecompetition due to i...

CUTTING CAPABILITY The PRO-CUT 80 is rated at 80 amps, at 60% dutycycle on a 10 minute basis or 60 amps, at 100% dutycycle. If the duty cycle is exceeded, a thermal protec-tor will shut off the output of the machine until it coolsto the normal operating temperature. Figure B.1 shows the cut capacity...

Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC OPERATION B-5 B-5 PRO-CUT 80 CONTROLS AND SETTINGS FIGURE B.2 - CASE FRONT CONTROLS OUTPUT CURRENT CONTROL KNOB - Adjust...

ELECTRIC SHOCK can kill. • Turn off machine at the discon- nect switch on the front of themachine before tightening,cleaning or replacing consum-ables. - Check the conditions of the inside of the nozzle. If debris has collected, rub the electrode on theinside bottom of the nozzle to remove any oxide...

THICK SECTIONS OF METAL Output set above 45 Amps. • The best quality and consumable life will be obtained by holding the torch off the surface about3/16 in. (4.7mm). Too long an arc may compromisecut quality and consumable life. The nozzle shouldNOT be dragged on the work. • Use of the S22151 Drag C...

MACHINE INTERFACE The PRO-CUT 80 comes standard with a machineinterface. Interface signals provided include: arc start,arc initiated, and arc voltage. These signals are acces-sible through the 14 pin MS connector on the casefront. ARC START: The Arc Start circuit allows for triggering of the powerso...

NOTES B-10 B-10 PRO-CUT 80 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC

TABLE OF CONTENTS - ACCESSORIES - Accessories ........................................................................................................................... Section C Options/Accessories........................................................................................................

GENERAL OPTIONS / ACCESSORIES The following options/accessories are available foryour PRO-CUT 80 from your local Lincoln Distributor. K1681-1 Undercarriage - A valet style undercarriage with pull-out handle for machine only. Provides torchand work cable storage. S22147-043 - Vortech™ nozzle with an ...

Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Section D-1 Section D-1 PRO-CUT 80 TABLE OF CONTENTS -MAINTENANCE- Maintenance ......................................................................................................................... Section D S...

ELECTRIC SHOCK can kill. • Have an electrician install and service this equipment. • Turn the input power off at the fuse box before working on equipment. • Do not touch electrically hot parts. • Prior to performing preventative maintenance, per- form the following capacitor discharge procedure toav...

Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC MAINTENANCE D-3 D-3 PRO-CUT 80 ROUTINE MAINTENANCE 1. Keep the cutting or gouging area and the area around the machine c...

6 4 3 5 1 2 Maintenance D-4 D-4 PRO-CUT 80 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC FIGURE D.2 – MAJOR COMPONENT LOCATIONS 1. Case Front2. Base and Case Back3. C...

Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Section E-1 Section E-1 PRO-CUT 80 Theory of Operation ............................................................................................................. Section E General Description ....................

GENERAL DESCRIPTION The PRO-CUT 80 is a constant current, continuouscontrol plasma cutting power source. The inverterbased power supply design is controlled by a micro-processor control board. The control system has asafety mechanism to insure that the nozzle and elec-trode are in place before cutti...

PRECHARGE AND PROTECTION The input voltage is rectified by the input rectifier. Theresultant DC voltage is applied, through the reconnectswitch, to the power board. The power board containsprecharging circuitry for the safe charging of the inputfilter capacitors. Once the capacitors are prechargedan...

THEORY OF OPERATION E-4 E-4 PRO-CUT 80 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC FIGURE E.4 – MAIN TRANSFORMER INPUT LINE SWITCH INPUT RECTIFIER FAN MOTOR "A&...

OUTPUT BOARD AND TORCH The output board contains an Insulated Gate BipolarTransistor (IGBT) which, upon receiving a pilot signal fromthe control board, either enables or disables the current inthe pilot winding. The cutting and pilot rectifier diodes arealso incorporated in the output board. There a...

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 processorinterprets these signals, makes decisions and changesmachine mode and output to satisfy the requirementsas defined by the inter...

PROTECTION CIRCUITS Protection circuits are designed into the PRO-CUT 80machine to sense trouble and shut down the machinebefore the trouble damages internal machine compo-nents. Both overload and thermal protection circuitsare included. OVERLOAD PROTECTION The PRO-CUT 80 is electrically protected f...

INSULATED GATE BIPOLAR TRANSISTOR (IGBT) OPERATION An IGBT is a type of transistor. IGBTs are semicon-ductors well suited for high frequency switching andhigh current applications. Drawing A shows an IGBT in a passive mode. Thereis no gate signal, zero volts relative to the source, andtherefore, no ...

PULSE WIDTH MODULATION The term PULSE WIDTH MODULATION describeshow much time is devoted to conduction in the posi-tive and negative portions of the cycle. Changing thepulse width is known as MODULATION. Pulse WidthModulation (PWM) is the varying of the pulse widthover the allowed range of a cycle t...

Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Section F-1 Section F-1 PRO-CUT 80 Troubleshooting & Repair Section ................................................................................. Section F How to Use Troubleshooting Guide ..................

Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC HOW TO USE TROUBLESHOOTING GUIDE Service and repair should be performed by only Lincoln Electric Factory Trained Personn...

ELECTRIC SHOCK can kill. Have an electrician install and servicethis equipment. Turn the machine OFFbefore working on equipment. Do nottouch electrically hot parts. Sometimes machine failures appear to be due to PCboard failures. These problems can sometimes betraced to poor electrical connections. ...

Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-4 F-4 PRO-CUT 80 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginnin...

Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-5 F-5 PRO-CUT 80 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginnin...

Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-6 F-6 PRO-CUT 80 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginnin...

Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-7 F-7 PRO-CUT 80 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginnin...

Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-8 F-8 PRO-CUT 80 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginnin...

Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-9 F-9 PRO-CUT 80 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginnin...

Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-10 F-10 PRO-CUT 80 INPUT FILTER CAPACITOR DISCHARGE PROCEDURE WARNING Service and repair ...

Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-11 F-11 PRO-CUT 80 ELECTRIC SHOCK can kill. • Have an electrician install and service thi...

Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-12 F-12 PRO-CUT 80 INPUT RECTIFIER TEST WARNING Service and repair should be performed by...

Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-13 F-13 PRO-CUT 80 INPUT RECTIFIER TEST (continued) TEST PROCEDURE 1. Remove main input p...

TEST POINT TERMINALS ANALOG METER X10 RANGE +Probe - Probe Acceptable Meter Readings Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-14 F...

PRIMARY POWER BOARD RESISTANCE TEST AND CAPACITOR VOLTAGE TEST Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result in danger to the technician ormachine operator and will invalidate your factory warrant...

Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-16 F-16 PRO-CUT 80 PRIMARY POWER BOARD RESISTANCE TEST AND CAPACITOR VOLTAGE TEST (contin...

Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-17 F-17 PRO-CUT 80 PRIMARY POWER BOARD RESISTANCE TEST AND CAPACITOR VOLTAGE TEST (contin...

Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-19 F-19 PRO-CUT 80 6. Check for the appropriate voltages outlined in Table F.3. NOTE: Vol...

OUTPUT POWER BOARD RESISTANCE TEST Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result in danger to the technician ormachine operator and will invalidate your factory warranty. For your safety and to av...

Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-21 F-21 PRO-CUT 80 OUTPUT POWER BOARD RESISTANCE TEST (continued) FIGURE F.4 – OUTPUT POW...

6. If any of the resistance checks are not correct, the output power board is faulty. Replace. See the Output Power Board Removal and ReplacementProcedure. 7. If the output power board “passes” the resistance test, the power diode and transistor portion of theboard is good. However, other circuits o...

TORCH CONTINUITY AND SOLENOID TEST Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result in danger to the technician ormachine operator and will invalidate your factory warranty. For your safety and to av...

AIR/GAS SOLENOID TEST Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result in danger to the technician ormachine operator and will invalidate your factory warranty. For your safety and to avoid elec-tric...

Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-26 F-26 PRO-CUT 80 AIR/GAS SOLENOID TEST (continued) TEST PROCEDURE 1. Remove input power...

Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-28 F-28 PRO-CUT 80 (T2) AUXILIARY TRANSFORMER TEST (continued) FIGURE F.8 – T2 AUXILIARY ...

TRIGGER CIRCUIT TEST Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result in danger to the technician ormachine operator and will invalidate your factory warranty. For your safety and to avoid elec-trica...

Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-31 F-31 PRO-CUT 80 TRIGGER CIRCUIT TEST (continued) FIGURE F.9 – SIMPLIFIED TRIGGER CIRCU...

TROUBLESHOOTING & REPAIR F-33 F-33 PRO-CUT 80 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TRIGGER CIRCUIT TEST (continued) G3439 PRO-CUT 80 OUTPUT LED1 LED2 D29...

CONTROL BOARD LED DEFINITIONS LED1: (Red) This light indicates that 18 VAC is being supplied to the control board from theauxiliary transformer. It also shows that the 18VAC is being rectified and should be regulated to+15 VDC. This +15 VDC supply is used to powerthe circuitry on the control board. ...

LOW VOLTAGE CIRCUIT TEST Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result in danger to the technician ormachine operator and will invalidate your factory warranty. For your safety and to avoid elec-t...

Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-36 F-36 PRO-CUT 80 FIGURE F.12 - LOW VOLTAGE CIRCUIT DIAGRAM #216 #219 15J40 10J40 6J2 9J...

Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-38 F-38 PRO-CUT 80 FIGURE F.13 – OUTBOARD LOW VOLTAGE CIRCUIT TEST POINTS AND LEDs G3439 ...

Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-39 F-39 PRO-CUT 80 LOW VOLTAGE CIRCUIT TEST (continued) CONTROL BOARD LED DEFINITIONS LED...

CONTROL BOARD REMOVAL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result in danger to the technician ormachine operator and will invalidate your factory warranty. For your safety and to...

Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-41 F-41 PRO-CUT 80 PROCEDURE 1. Remove input power to the PRO-CUT 80 machine. 2. Remove t...

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 gentlyextracting the plugs from the P.C. boardreceptacles. 7. Using the needle-nose pliers and screwdriv- er, gently remove the...

DISPLAY BOARD REMOVAL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result in danger to the technician ormachine operator and will invalidate your factory warranty. For your safety and to...

Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-44 F-44 PRO-CUT 80 PROCEDURE 1. Remove the input power to the PRO-CUT 80 machine. 2. Remo...

5. Locate the display P.C. board and the one plug connected to it. See Figure F.20. 6. Gently remove the display P.C. board from the three mounting pins. Be sure to follow the recommended static-freemethods for handling printed circuit boards.Failure to do so can result in permanent damageto the equ...

OUTPUT POWER BOARD REMOVAL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result in danger to the technician ormachine operator and will invalidate your factory warranty. For your safety a...

TROUBLESHOOTING & REPAIR F-47 F-47 PRO-CUT 80 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC FIGURE F.21 – OUTPUT POWER BOARD REMOVAL OUTPUT POWER BOARD REMOVAL &a...

TROUBLESHOOTING & REPAIR F-48 F-48 PRO-CUT 80 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC FIGURE F.22 – OUTPUT BOARD LEAD LOCATIONS G3439 PRO-CUT 80 OUTPUT LED1...

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 heatsink. Make sure the surfaces are clean. Donot allow the compound to get into thethreaded holes or on the screw threads. Be sure to follow the recomme...

PRIMARY POWER BOARD AND FILTER CAPACITOR REMOVAL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result in danger to the technician ormachine operator and will invalidate your factory warra...

TROUBLESHOOTING & REPAIR F-51 F-51 PRO-CUT 80 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC FIGURE F.23 – PRIMARY POWER BOARD REMOVAL PRIMARY POWER BOARD AND FILT...

TROUBLESHOOTING & REPAIR F-52 F-52 PRO-CUT 80 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC FIGURE F.24 – POWER BOARD HEATSINK AND CAPACITOR REMOVAL PRIMARY POWER...

CAPACITOR REMOVAL 1. Using the 3/8” wrench, remove the four screws holding the heat sink to the centerpanel assembly. Take note of the insulator placement for reassembly. The four screws have insulating washers on both sides of thepanel assembly. These must be properlyreplaced upon reassembly. 2. Ca...

INPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result in danger to the technician ormachine operator and will invalidate your factory warranty. For your safe...

TROUBLESHOOTING & REPAIR F-55 F-55 PRO-CUT 80 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC FIGURE F.25 – INPUT RECTIFIER LEAD LOCATIONS #207A #207 #209 A B C INP...

TROUBLESHOOTING & REPAIR F-56 F-56 PRO-CUT 80 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC INPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued) 7. Carefull...

Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-57 F-57 PRO-CUT 80 RETEST AFTER REPAIR Should a machine under test be rejected for any re...

G-1 ELECTRICAL DIAGRAMS G-1 PRO-CUT 80 TABLE OF CONTENTS -ELECTRICAL DIAGRAMS SECTION- ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION G WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

ELECTRICAL DIAGRAMS G-2 PRO-CUT 80 WIRING DIAGRAM - PRO CUT 80 1 ++VOLT 6 RELAY 12 GND 11 TRIGGER 3 IGBT 2,6 PSI SWITCH 10 ELEC SOL 9 AIR SOL 2 1 4 7 2 1 0 2 7 5 J 2 2 1 2 1 6 8 A H 4 TP2 18V FRONT OF MACHINE 3 8 M A I N P_XFMR 7 X F M R 2 0 2 10 PSI SET ELEC XFER 1 1,2 TRIGGER + 2 0 4 4 ELECTRODE 2...

ELECTRICAL DIAGRAMS G-3 PRO-CUT 80 SCHEMATIC - CONTROL PC BOARD LT1014 LT1014 TCF6000 ELECTRODE SHUNT GAIN = 80.0 1V = 12.50 A TCF6000 1V = 68.07mA LM224 X 1 6 5 10.0K R94 C O M SHUNT 1.00K R88 1 . 0 A3 0 V D 2 1 B O A R D O U T P U T J 3 5 C 5 3 V V INPUT CC EE N C O U T INPUT N U L L 4 N U L L 7 O...

ELECTRICAL DIAGRAMS G-6 PRO-CUT 80 SCHEMATIC - POWER PC BOARD C3 C1 E2 E4 C2 E3 G2 C4 E1 A 2 G4 G3 G1 C A P A C I T O R A 1 A 1 C 1 A 1 A 2 C 1 2 0 8 P R I M A R Y ( V O L T A G E P R O T E C T I O N ) 1 . 0 0 K R 9 7 221K R44 T R A N S F O R M E R P R I M A R Y 3 2 5 V D C ( N O M I N A L ) T R A N...

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....

ELECTRICAL DIAGRAMS G-8 PRO-CUT 80 SCHEMATIC - OUTPUT PC BOARD OCI1 Vcc GND HP2201 5 8 NOZZLE CHASSIS ELECTRODE J32 10 400V .1 C33 15W 1.5K R51 A1 C A T12705-56 5 6 B12 15W 1.5K R53 15W 1.5K R66 C34 15W 1.5K R52 15W 1.5K R50 15W 1.5K R65 A1 C A T12705-56 1 2 3000V .0047 C37 3000V .0047 C30 180J 480V...

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....

ELECTRICAL DIAGRAMS G-10 PRO-CUT 80 SCHEMATIC - DISPLAY PC BOARD L E D 4 5 6 1 2 J 4 0 3 L E D 5 7 8 J 4 0 12 3 4 8 7 L E D 3 7 8 5 6 J 4 0 4 1 2 4 3 1 0 0 R 1 2 5 0 V 2 7 0 0 p C 3 6.81K R10 3 . 3 2 K R 9 J 4 0 8 J 4 0 9 Q 3 2 N 4 4 0 1 1 0 0 R11 C O M + 1 5 V + 1 5 V + 1 5 V C O M C O M C O M + 1 ...

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....

SVM ERROR REPORTING FORM We need to know if there are errors in our manuals. We also value any suggestions as toadditional 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 troubleshoo...