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Lincoln Electric Pro-Cut 55, Service Manual

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Lincoln Electric Pro-Cut 55 Service Manual Download Page 115

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
machine.

ELECTRICAL DIAGRAMS

G-8

PROCUT 55

PC BOARD ASSEMBLY-CONTROL (G3328-1)

 J1  

 J3  

 J4  

 J2  

 J5  

 TP1 

 TP2 

D1   

D2   

D3   

D4   

 C1  

X9   

 X7  

 X8  

C5   

R5   

R6   

R7   

R8   

R9   

R10  

 C6 

D9   

D6   

D8   

D7   

 C3  

 R1  

D5   

R2   

R3   

R4   

 X5  

X12  

X1   

X3   

  X6  

  X4  

X2   

  X10 

C64  

C66  

C63  

C65  

R39  

R38  

C35  

C15  

R33  

R32  

C16  

C37  

C36  

C47  

R34  

R37  

R94  

R93  

R42  

R27  

R30  

R36  

R26  

R28  

C68  

C2   

C8   

C69  

R102 

R87  

R99  

R29  

R58  

R67  

R91  

R100 

R101 

C39  

R56  

R57  

C30  

R115 

R116 

R117 

R118 

R54  

R55  

C28  

R45  

C21  

R52  

R53  

R153 

R49  

C26  

  X16 

R152 

R96  

R103 

R72  

D14  

C24  

R46  

R40  

C53  

C23  

C43  

C10  

R35  

C17  

R24  

C31  

R48  

R97  

C44  

C45  

R78  

R79  

C22  

R59  

R149 

R89  

R98  

R88  

D21  

D23  

R85  

R84  

R83  

R120 

R121 

R122 

R123 

 C56 

D15  

D16  

D17  

D18  

R13  

R14  

R12  

R11  

R17  

R19  

C13  

R124 

R125 

R126 

R127 

R128 

R129 

R142 

R143 

R144 

R145 

R146 

R147 

C57  

D10  

D11  

D13  

C32  

C33  

R131 

R132 

R133 

R134 

R135 

R130 

C54  

C55  

R138 

R139 

R141 

R137 

 C19 

C61  

C62  

C42  

 C50 

C58  

C60  

D12  

D20  

R110 

R111 

R104 

R109 

R47  

C40  

R76  

C41  

R61  

R62  

R63  

R68  

R69  

R95  

R106 

R108 

R112 

R113 

R114 

R136 

 Y1  

R44  

R43  

R31  

D22  

C52  

C48  

C46  

C34  

 C25 

C20  

C14  

PRO-CUT 50 CONTROL

C18  

 X11  

  Q3  

  Q2  

  Q1  

 C7  

 C9  

C29  

C59  

DZ1  

DZ2  

D25  

D26  

D27  

R20  

R22  

R140 

R154 

R155 

R156 

R157 

R158 

R159 

R160 

R164 

R165 

R166 

R167 

R900 

G3328-1

C4   

 LED1 

 LED2 

 LED3 

R21  

R23  

R70  

R73  

R77  

R80  

R81  

R82  

R107 

R51  

R119 

R170 

R171 

R172 

X18  

R173 

R174 

R175 

R176 

R177 

C73  

R178 

R179 

R180 

R181 

R182 

C71  

  X15 

C74  

C75  

  Q4  

R184 

R183 

 X13 

 X14 

 R18 

C72  

 Q5  

R168 

D19  

R169 

D28  

R901  

ITEM

REQ'D

PART NO.

DESCRIPTION

  C1                              

 

1     

S13490-92       3300/50                                       

  C2,C8,C10,C13,C14,C17,C20      

31     

S16668-5        .022/50                                           

  C23,C24,C29,C31,C34,C35       
  C36,C37,C39,C40,C41,C47       
  C53,C55,C58,C63,C64,C65       
  C66,C68,C69,C73,C74,C75
  C3                              

 

1     

S13490-121      1000/35                                       

  C4,C18                          

 

2     

S13490-63       .47/50                                        

  C5                              

 

1     

S13490-71       100/50                                        

  C6                              

 

1     

T11577-52       .0047 or .005/1400                            

  C7,C9                           

 

2     

S13490-93       27/35                                         

  C15,C16,C32,C33,C42             

5     

S16668-11       .1/50                                         

  C19,C25,C50                     

 

3    

 S13490-25       4.7/35                                        

  C21,C26,C28,C30,C54,C57         

8     

S13490-42       1.0/35                                            

  C62,C71
  C22,C43,C44                     

 

3     

S16668-9        150pF/100                                     

  C46,C52                         

 

2     

S16668-13       10pF/100                                      

  C48                             

 

1     

S16668-8        330pF/100                                     

  C56                             

 

1     

S13490-108      .15/100                                       

  C59                             

 

1     

S16668-3        100pF/100                                     

  C60                             

 

1     

S13490-126      .018/50V                                      

  C61                             

 

1     

S13490-19       1.8/20                                        

  C72                             

 

1     

S16668-10       4700pF/50                                     

  D1,D2,D3,D4,D5,D6,D7,D8,D9     

16     

T12199-1        1N4004                                            

  D10,D11,D12,D13                  4     

T12705-37       1N5822 SCHOTTKY BARRIER DIODE                 

  D15,D16,D17,D18,D21             

5     

T12705-34       1N4936                                        

  DZ1,DZ2                         

 

2     

T12702-19       1N4742A                                       

  J1                              

 

1     

S18248-4        HEADER                                        

  J2                              

 

1     

S18248-10       HEADER                                        

  J3                              

 

1     

S18248-16       HEADER                                        

  J4                              

 

1     

S18248-6        HEADER                                        

  J5                              

 

1     

S18248-8        HEADER                                        

  LED1,LED2,LED3                   3     

T13657-2        RED LED                                       

  Q1,Q2,Q3                        

 

3     

T12704-68       2N4401                                        

  Q4                              

 

1     

T12704-80       HEXFET TRANS. (SS)                            

  R1                              

 

1     

T13165-16       1.0 OHM, 5W RESISTOR                          

  R2,R46,R132                     

 

3     

S19400-2671     2.67K 1/4W                                    

  R3,R30,R32,R33,R34,R36,R37      

9     

S19400-2430     243 1/4W                                          

  R38,R39

  R4                              

 

1     

S19400-30R1     30.1 1/4W                                     

  R5                              

 

1     

S19400-6190     619 1/4W                                      

  R6                              

 

1     

S19400-8251     8.25K 1/4W                                    

  R7                              

 

1     

S19400-3921     3.92K 1/4W                                    

  R8                              

 

1     

S19400-2001     2.0K 1/4W                                     

  R9,R88,R103                    

 

3     

S19400-1001     1K 1/4W                                       

  R10,R42,R95,R96                  4     

S19400-5110     511 1/4W                                      

  R11,R12,R13,R14                  4     

S19400-3320     332 1/4W                                      

  R17,R26,R27,R49,R51,R59       

 35     

S19400-1002     10K 1/4W                                          

  R61,R62,R63,R68,R69,R81       

  R153,R154,R156,R158,R160      

  R179,R180,R181,R182
  R18                             

 

1     

S24073-1        10K,1/2W,TRIMMER                              

  R19,R47,R53,R55,R57,R85         

8     

S19400-5111     5.11K 1/4W                                        

  R144,R145,R146,R147.R901
  R21,R23                         

 

2     

S19400-1822     18.2K 1/4W                                    

  R77                             

 

1     

S19400-2211     2.21K 1/4W                                    

  R24,R35                         

 

2     

S19400-2210     221 1/4W                                      

  R28,R112,R115,R116,R117         

7    

S19400-3321     3.32K 1/4W                                        

  R118,R119
  R29,R91,R102                      

3     

S19400-8250     825 1/4W                                      

  R31                             

 

1     

S19400-1004     1M 1/4W                                       

  R43,R44,R45,R136,R137,R170     

 8    

 S19400-4751     4.75K                                             

  R171,R172
  R48,R67,R70,R87,R101            

5     

S19400-4752     47.5K 1/4W                                    

  R52,R54,R56                     

 

3     

S19400-1000     100 1/4W                                      

  R82,R175,R177                     

3     

S19400-1301     1.3K 1/4W                                     

  R79,R83,R155,R167               4     

S19400-2213     221K 1/4W                                     

  R80,R89                         

 

2     

S19400-1003     100K 1/4W                                     

  R98                             

 

1     

S19400-2431     2.43K 1/4W                                    

  R109                            

 

1     

S19400-6811     6.81K 1/4W                                    

  R120,R121,R122,R123             

4     

S19400-26R7     26.7 1/4W                                     

  R130                            

 

1     

S19400-2212     22.1K 1/4W                                    

  R131,R174                       

 

2     

S19400-6812     68.1K 1/4W                                    

  R133,R173                       

 

2     

S19400-2672     26.7K 1/4W                                    

  R140,R141                       

 

2     

S19400-2670     267 1/4W                                      

  R135,R183                       

 

2     

S19400-1502     15K 1/4W                                      

  R176                            

 

1     

S19400-4750     475 1/4W                                      

  R129,R184                       

 

2     

S19400-5621     5.62K 1/4W                                    

  TP1,TP2                         

 

2     

T13640-15       15J                                           

  X1,X2                           

 

2     

S15128-16       LINEAR INTEGRATED CIRCUIT                     

  X3                              

 

1     

S15128-4        LM224 OP-AMP                                  

  X4,X6                           

 

2     

S15128-13       PRECISION OP AMP IC                           

  X7                              

 

1     

S18647          REGULATOR ASBLY                               

  X8                              

 

1     

S18395-13       5V REG. ASBLY                                 

  X9                              

 

1     

S15128-12       VOLTAGE REGULATOR                             

  X10,X16                         

 

2     

S15018-18       IC,ARRAY,CLAMPING                             

  X11                             

 

1     

M15102-3     RESET I.C. UNDERVOLT. SENSING CIR. (SS)         

  X12                             

 

1     

M15458-2        PWM CONTROLLER I.C. (SS)                      

  X15                             

 

1     

M15105-8        CMOS,CONVERTER,D/A,SERIAL,10-BIT (SS)         

  X18                             

 

1     

M13552-2        FREQ. TO VOLTAGE CONVERTER                    

  Y1                              

 

1     

S16665-5        8.0 MHZ                                       

D14,D20,D22,D23,D25       

D26,D27

  Q5                              

 

1    

T12704-69       HEXFET TRANS. (SS)                            

  X13,X14                         

 

2     

S15018-19       IC, DRIVER, FET, 6A                            

  R72, R900                       

 

2     

S19400-1501     1.5K 1/4W                                     

  R40,R73,R107                   

 

3    

 S19400-7681     7.68K 1/4W                                    

R164,R165,R166,R178      

R84,R93,R94,R104,R106,R108    

  R58,R76,R99,R100                 4     

S19400-3741     3.74K 1/4W                                    

                     X5                              

                  1                    S24085-1        ROM ASSEMBLY                                  

  R149,R157

  C45                             

 

1     

S16668-4        2700pF/50                                      

R134,R138,R139,R152      

  R20,R22,R110,R111,R124,R125     

16     

S19400-10R0     10 1/4W                                           

  R126,R127,R128,R142,R143      

  R78,R113,R114,R159      

          

4     

S19400-1211     1.21K 1/4W                                    

  R97                             

 

1     

S19400-8252     82.5K 1/4W                                     

G-8

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Summary of Contents for Pro-Cut 55

Page 1: ...NED THROUGHOUT And most importantly think before you act and be careful For use with machine code numbers Below 11000 PRO CUT 55 Return to Master TOC Return to Master TOC Return to Master TOC Return t...

Page 2: ...he arc nor expose themselves to the arc rays or to hot spatter or metal ELECTRIC SHOCK can kill 1 a The electrode and work or ground circuits are electrically hot when the power source is on Do not to...

Page 3: ...ric current flowing through any conduc 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 i...

Page 4: ...Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES iii iii PRO CUT 55...

Page 5: ...ion B Accessories Section C Maintenance Section D Theory of Operation Section E Troubleshooting and Repair Section F Safety Precautions F 2 How to Use Troubleshooting Guide F 2 Troubleshooting Guide F...

Page 6: ...pecifications A 2 Safety Precautions A 4 Select Suitable Location A 4 Stacking A 4 Lifting and Moving A 4 Tilting A 4 High Frequency Interference Protection A 4 Input Electrical Connections A 5 Ground...

Page 7: ...d Output Amps Voltage and Hertz 208 1 60 60 55 230 1 60 55 55 460 1 60 30 55 208 1 60 44 40 230 1 60 40 40 460 1 60 23 40 Three Phase Input Input Currents Rated Output Amps Voltage and Hertz 208 3 60...

Page 8: ...SIZES For all plasma cutting 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...

Page 9: ...carriage 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 Eithe...

Page 10: ...d input power cord already connected to the machine A cord connector provides a strain relief for the input power cord as it passes through the left rear access hole The cord connector is designed for...

Page 11: ...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 FIGURE A 2 RECONNECTION DIAGRAM INSTALLATION A 6 A 6 PRO CUT 55 Return to Sect...

Page 12: ...e 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 CYLINDER could explode if damaged Keep cylinder uprig...

Page 13: ...ut with a quick connect at the case front for easy change over See Figure A 4 For more information on the torch and its components refer to the PCT 80 Operators Manual IM588 FIGURE A 4 TORCH CONNECTIO...

Page 14: ...Equipment B 3 Operational Features and Controls B 3 Design Features and Advantages B 3 Cutting Capability B 4 Consumable Life B 4 Limitations B 4 Controls and Settings B 5 Pilot Arc Considerations B...

Page 15: ...elf from the work and ground Always wear dry insulating gloves FUMES AND GASES can be dangerous Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone CUTTING SPARK...

Page 16: ...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 BUTTO...

Page 17: ...y 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 electro...

Page 18: ...sumable 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 d...

Page 19: ...ting speed so that the arc lag is 10 to 20 behind the travel direction Use a 5 15 leading angle in the direction of the cut Use the drag cup to maintain constant standoff for better cut quality and to...

Page 20: ...hose 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 CUT...

Page 21: ...de buildup Replace the nozzle turn on the power and continue cutting If the Parts in Place circuit safety status indicator light continues to trip after cleaning the consum ables replace them with a n...

Page 22: ...TABLE OF CONTENTS ACCESSORIES Accessories Section C Options Accessories C 2 Section C 1 Section C 1 PRO CUT 55 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC...

Page 23: ...uching the workpiece S22151 Drag Cup The drag cup protects the torch by preventing the torch from touching the workpiece K1571 Series PCT 80 Torches come in 25 and 50 lengths in either hand held or me...

Page 24: ...urn to Master TOC Return to Master TOC Section D 1 Section D 1 PRO CUT 55 TABLE OF CONTENTS MAINTENANCE Maintenance Section D Safety Precautions D 2 Input Filter Capacitor Discharge Procedure D 2 Rout...

Page 25: ...wo capacitor terminals large hex head cap screws on the top and bottom of the Power Board shown in Figure D 1 6 Use electrically insulated gloves and insulated pli ers Hold the body of the resistor an...

Page 26: ...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 ELECTRI...

Page 27: ...Machine Base 8 Auxiliary Transformer 9 Main Transformer Maintenance D 4 D 4 PRO CUT 55 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Retu...

Page 28: ...ATION SECTION INPUT LINE SWITCH INPUT RECTIFIER FAN MOTORS A L E A D AUXILIARY TRANSFORMER OUTPUT CONTROL AIR PRESSURE SWITCH P R O T E C T O N I SIGNAL CR 1 DRIVE SIGNAL RELAY IGBT GATE SIGNALS R E A...

Page 29: ...he auxiliary transformer develops the appropriate AC voltages to operate the cooling fans the control board and the plasma output board THEORY OF OPERATION E 2 E 2 PRO CUT 55 Return to Section TOC Ret...

Page 30: ...deactivate the CR1 input relay The machine output will also be disabled THEORY OF OPERATION E 3 E 3 PRO CUT 55 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC R...

Page 31: ...rough 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 wi...

Page 32: ...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...

Page 33: ...55 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FIGURE E 6 CONTROL AND D...

Page 34: ...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 outp...

Page 35: ...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 com...

Page 36: ...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...

Page 37: ...NOTES E 10 E 10 PRO CUT 55 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC...

Page 38: ...ower Board Resistance Test and Capacitor Voltage Test F 18 Output Power Board Resistance Test F 24 Torch Continuity and Solenoid Test F 28 Air Gas Solenoid Test F 32 T2 Auxiliary Transformer Test F 34...

Page 39: ...SSIBLE 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 duc...

Page 40: ...pment Do not touch electrically hot parts 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 coul...

Page 41: ...o fan no status indicator lights 1 Make sure that the input power switch is in the ON position 2 Check the input voltage at the machine Input voltage must match the rating plate and the reconnect pane...

Page 42: ...Voltage Test 2 Perform the Input Rectifier Test 3 The control board may be faulty Replace 4 The primary power board may be faulty Replace The machine powers up properly but there is no response when t...

Page 43: ...flow is not restricted 4 Make sure the air hose and screen are not clogged 1 Perform the Torch Continuity and Solenoid Test 2 The output board may be faulty Replace 3 The control board may be faulty R...

Page 44: ...MS The pilot arc is normal but the arc will not transfer to the workpiece 1 Make sure the operating proce dure is correct for the process See the Operation section of this manual 2 Make sure the work...

Page 45: ...e 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 1 The pressure switch S5 or associated leads may be faulty See the Wiring Diagram 2 Th...

Page 46: ...Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 PROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENT S RECOMMENDED COURSE OF ACTION LED FUNCTION PROBL...

Page 47: ...r Board Resistance Test Perform the Auxiliary Transformer Test Perform the Input Rectifier Test Are all LED s lit The microprocessor is faulty replace the control board Are all LED s off Perform the A...

Page 48: ...NOTES F 11 F 11 PRO CUT 55 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC...

Page 49: ...ase 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 Li...

Page 50: ...resistor is not supplied with machine NEVER USE A SHORTING STRAP FOR THIS PROCEDURE 5 Locate the four capacitor terminals large hex head cap screws shown in Figure F 1 One pair is at the top and one...

Page 51: ...cian 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...

Page 52: ...EST PROCEDURE 1 Remove main input power to the machine 2 Perform the Input Filter Capacitor Discharge Procedure detailed earlier in this section 3 Locate the input rectifier D1 and lead loca tions See...

Page 53: ...sure to recon nect leads 207 207A and 209 to the cor rect terminals and torque to 31 in lbs Apply a coating of Essex D 4 8 insulating com pound 8 If the input rectifier is faulty see the Input Rectifi...

Page 54: ...NOTES F 17 F 17 PRO CUT 55 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC...

Page 55: ...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 understan...

Page 56: ...RY POWER BOARD WITH INPUT FILTER CAPACITORS CAPACITOR C2 TERMINALS CAPACITOR C1 TERMINALS PRO CUT POWER G3172 207 202 206 203 201 204 205 208 TEST PROCEDURE 1 Remove main input power to the Pro Cut 55...

Page 57: ...an 100 ohms 205 203A Greater than 1000 ohms 203A 205 Less than 100 ohms 208 203A Greater than 1000 ohms 203A 208 Less than 100 ohms 206 208 Greater than 1000 ohms 208 206 Less than 100 ohms 206 205 Gr...

Page 58: ...ower 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 test locations on the primary powe...

Page 59: ...revent output 7 If the test voltages do not meet the expect ed values as listed in Table F 3 the capaci tors or other components on the power board may be faulty Replace NOTE If the capacitor voltages...

Page 60: ...NOTES F 23 F 23 PRO CUT 55 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC...

Page 61: ...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 throughou...

Page 62: ...CATIONS TEST PROCEDURE 1 Remove input power to the Pro Cut 55 machine 2 Perform the Input Filter Capacitor Discharge Procedure detailed earlier in this section 3 Remove the torch assembly from the mac...

Page 63: ...1 Less than to and 100 ohms Probe Terminal B11 associated trace Probe Terminal B11 Diode A1 Greater than to and 1000 ohms Probe J33 Pin4 associated trace Probe J33 Pin4 Diode A1 Less than to and 100 o...

Page 64: ...NOTES F 27 F 27 PRO CUT 55 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC...

Page 65: ...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 re...

Page 66: ...ch assembly from the machine 3 Using the ohmmeter check the torch resis tances per Table F 5 NOTE Take the Pin test point measurements at the machine end of the torch assem bly See Figure F 5 FIGURE F...

Page 67: ...0 ohm maximum Torch consumables Nozzle nozzle in place Pin 8 to Torch One pilot arc lead to 1 0 ohm maximum Torch consumables Nozzle nozzle in place Pin 1 to Pin 9 Torch trigger circuit 100K ohms min...

Page 68: ...NOTES F 31 F 31 PRO CUT 55 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC...

Page 69: ...e 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...

Page 70: ...pin 5 Normal resis tance is approximately 20 ohms If the resis tance is abnormal check the continuity zero or very low resistance of leads 366 and 361 between the solenoid and plug J31 See the Wiring...

Page 71: ...d 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 und...

Page 72: ...move main input power to the Pro Cut 55 machine 2 Perform the Input Filter Capacitor Discharge Procedure detailed earlier in this section 3 Locate the auxiliary transformer just behind the input line...

Page 73: ...ter TOC Return to Master TOC Return to Master TOC Return to Master TOC T2 AUXILIARY TRANSFORMER TEST continued TEST POINT TEST POINT EXPECTED VOLTAGE H1 1J22 H2 4J22 200 208VAC H1 1J22 H4 3J22 380 415...

Page 74: ...NOTES F 37 F 37 PRO CUT 55 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC...

Page 75: ...rator 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...

Page 76: ...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 5 If less than one ohm is read only when the to...

Page 77: ...ilter Capacitor Discharge Procedure 11 Check the continuity of leads 344 and 312 between the output board and the control board See Figure F 9 the Simplified Trigger Circuit Diagram and Figure F 10 12...

Page 78: ...his DC voltage is used to power the trigger circuit and solenoid driver circuits incorporated on the output board LED3 Green This light indicates that the air solenoid driver circuit is functioning Wh...

Page 79: ...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 recti...

Page 80: ...NOTES F 43 F 43 PRO CUT 55 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC...

Page 81: ...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...

Page 82: ...esence of approximately 28 VDC on the output board a LED1 should be lit when 28 VDC is present See Figure F 13 See Output Board LED Definitions and Figure F 12 Low Voltage Circuit Diagram b To verify...

Page 83: ...9 See Figure F 15 and Figure F 12 Low Voltage Circuit Diagram 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 boa...

Page 84: ...C voltage is used to power the trigger circuit and solenoid driver circuits incorporated on the output board LED3 Green This light indicates that the air solenoid driver circuit is functioning When th...

Page 85: ...DC 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...

Page 86: ...NOTES F 49 F 49 PRO CUT 55 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC...

Page 87: ...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...

Page 88: ...put Filter Capacitor Discharge Procedure 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...

Page 89: ...the eight mounting pins and gently slide the P C board onto the mounting pins until the board snaps onto the pins 9 Replace the five molex type plugs in their respective receptacles Be certain they a...

Page 90: ...NOTES F 53 F 53 PRO CUT 55 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC...

Page 91: ...ger 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 t...

Page 92: ...the wraparound cover and perform the Input Filter Capacitor Discharge Procedure detailed earlier in this section 3 Using the 5 16 nut driver remove the four screws holding the front assembly to the t...

Page 93: ...static free methods for handling printed circuit boards Failure to do so can result in permanent damage to the equipment 7 Depress the locking tab and remove the plug connector from the display board...

Page 94: ...NOTES F 57 F 57 PRO CUT 55 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC...

Page 95: ...te 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 tes...

Page 96: ...to Master TOC FIGURE F 21 OUTPUT POWER BOARD REMOVAL OUTPUT POWER BOARD OUTPUT POWER BOARD REMOVAL REPLACEMENT continued PROCEDURE 1 Remove input power to the Pro Cut 55 machine 2 Remove the case wrap...

Page 97: ...X4 X2 and B21 from the output power board 5 Remove all plugs from the output power board 6 Remove leads X20 and X40 from the output power board 7 Using the phillips head screw driver remove the two s...

Page 98: ...eat 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 5 Replace lead...

Page 99: ...our 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 pr...

Page 100: ...APACITORS PRIMARY POWER BOARD AND FILTER CAPACITOR REMOVAL AND REPLACEMENT continued REMOVAL PROCEDURE 1 Remove input power from the Pro Cut 55 machine 2 Remove the case wraparound and perform the Inp...

Page 101: ...OWER BOARD AND FILTER CAPACITOR REMOVAL AND REPLACEMENT continued 7 Using the slot head screw driver remove the two mounting screws from the left side of the primary power board See Figure F 24 Take n...

Page 102: ...with the correct capacitor polari ties 4 Assemble the four socket head screws and pre torque them to 25 inch pounds 5 Make certain the capacitors are lined up correctly so that when the capacitor bol...

Page 103: ...y 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 o...

Page 104: ...LACEMENT continued PROCEDURE 1 Remove input power to the Pro Cut 55 2 Perform the Input Filter Capacitor Discharge Procedure detailed earlier in this section 3 Locate the input rectifier and the leads...

Page 105: ...ully 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 scr...

Page 106: ...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...

Page 107: ...NOTES F 70 F 70 PRO CUT 55 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC...

Page 108: ...ematic L10722 G 3 Power P C Board Schematic L10616 G 4 Display P C Board Assembly L10721 1 G 5 Display Board M18920 G 6 Control Schematic G3327 G 7 Control P C Board Assembly G3328 1 G 8 Control P C B...

Page 109: ...312 344 302 J5 501 502 503 505 506 507 J4 401 404 2 E D1 8 N 3 N 4 5 9 U 62 64 W 61 U J3 J32 J40 S3 PSI_SET S2 RESET 1 3 4 2 1 3 7 6 5 8 4 9 10 2 1 3 5 4 7 6 8 9 10 15 11 12 13 14 J40 212 214 213 215...

Page 110: ...n to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G 3 PROCUT 55 SCHEMATIC PLASMA OUTPUT BOARD G 3 NOTE This diagram is for refere...

Page 111: ...his diagram is for reference only It may not be accurate for all machines covered by this manual Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Maste...

Page 112: ...C C C C C C J40 RA A c C C C C C C C c C C C C C C C c C C C C C C C c C C C C C C C c C C C C C C C c C C C C C C C c C C C C C C C c C C C C C C C L10721 1 c C C C B B b B B b B B b B B b DISPLAY 0...

Page 113: ...rn to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G 6 PROCUT 55 SCHEMATIC DISPLAY PC BOARD G 6 NOTE This diagram is for referenc...

Page 114: ...This diagram is for reference only It may not be accurate for all machines covered by this manual Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Mast...

Page 115: ...DIODE D15 D16 D17 D18 D21 5 T12705 34 1N4936 DZ1 DZ2 2 T12702 19 1N4742A J1 1 S18248 4 HEADER J2 1 S18248 10 HEADER J3 1 S18248 16 HEADER J4 1 S18248 6 HEADER J5 1 S18248 8 HEADER LED1 LED2 LED3 3 T13...

Page 116: ...nly 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 boa...

Page 117: ...ly 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 boar...

Page 118: ...ly 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 boar...

Page 119: ...W R18 R77 2 S19400 1821 1 82K 1 4W R19 1 S19400 2673 267K 1 4W R28 1 T10812 41 10K 1 2W TRIMMER R29 R30 R31 R32 R71 R72 8 T14648 12 1500 OHM 5 WATT RESISTOR R73 R74 R33 R38 R58 3 S19400 3321 3 32K 1 4...

Page 120: ...nly 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 boa...

Page 121: ..._ ___________________________________________________________________________ ___________________________________________________________________________ ______________________________________________...

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