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Lincoln Electric PRO-CUT 60, Service Manual, Page: 28 / 114

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SAFETY PRECAUTIONS

ELECTRIC SHOCK can kill.

• Only qualified personnel

should perform this mainte-
nance.

• Turn the input power OFF at

the disconnect switch or fuse
box before working on this
equipment.

• Failure to follow this capaci-

tor discharge procedure can
result in electric shock.

• Do not touch electrically hot

parts.

CAPACITOR DISCHARGE PROCEDURE

PROCEDURE  DESCRIPTION

This procedure must be performed before per-
forming any maintenance inside the machine.

MATERIALS NEEDED

High resistance, high wattage resistor

( 25-1000 ohms, 25 watts minimum).

Insulated pliers
Insulated gloves
DC Volt/Ohm meter (Multimeter)

MAINTENANCE

PRO-CUT 60

D-1

WARNING

Summary of Contents for PRO-CUT 60

Page 1: ...OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful ON OFF o 1 ON OFF o 1 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 World s Leader in Welding and Cutting Products ...

Page 2: ...g Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PER FORMED ONLY BY QUALIFIED INDIVIDUALS ARC RAYS can burn 2 a Use a shield with the proper filter and cove...

Page 3: ...ting sparks from start ing a fire Remember that welding or cutting sparks and hot materials from welding or cutting can easily go through small cracks and openings to adjacent areas Avoid welding or cut ting near hydraulic lines Have a fire extinguisher readily available 4 b Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Ref...

Page 4: ...te engines in open well ventilated areas or vent the engine exhaust fumes outdoors ____________________________________________________ 7 c Do not add the fuel near an open flame welding or cutting arc or when the engine is running Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting Do not spill fuel when filli...

Page 5: ...ge à l aide d écrans appropriés et non inflammables 4 Des gouttes de laitier en fusion sont émises de l arc de soudage Se protéger avec des vêtements de protection libres de l huile tels que les gants en cuir chemise épaisse pan talons sans revers et chaussures montantes 5 Toujours porter des lunettes de sécurité dans la zone de soudage Utiliser des lunettes avec écrans lateraux dans les zones où ...

Page 6: ...s and Controls B 2 Design Features and Advantages B 2 Cutting and Gouging Capability B 3 Limitations B 3 Controls and Settings B 3 Operating Steps B 4 Cutting Procedure Recommendations B 5 Accessories Section C Accessories C 1 Maintenance Section D Safety Precautions D 1 Routine and Periodic Maintenance D 1 3 D Exploded View D 2 Theory of Operation Section E Power Supply Operation E1 E 5 SCR Opera...

Page 7: ...autions A 2 Select Proper Location A 2 Stacking A 2 Tilting A 2 High Frequency Interference Protection A 2 Input Electrical Connections A 3 Fuses and Wire Sizes A 4 Ground Connection A 4 Input Power Supply Connections A 4 Air Input Connections A 5 Reconnect Procedure A 6 Output Connections A 7 Section A TABLE OF CONTENTS INSTALLATION SECTION PRO CUT 60 ...

Page 8: ...uty Cycle 100 Duty Cycle Current Range 25 60 Amps AC Input Voltage at 60 Hertz 208 230 460 575 Fuse Super Lag Circuit Breaker Delay Type 50 AMPS 25 AMPS 8 8 4mm2 10 5 3mm2 2 Input Supply Wires 1 Ground Wire 10 5 3mm2 10 5 3mm2 Type 75o C Copper Wire in Conduit AWG IEC Sizes Depth 22 in 559 mm Width 19 in 483 mm Height 34 in 864 mm Open Circuit Voltage MIN MAX 235VAC 280 VAC For all plasma cutting ...

Page 9: ...FREQUEN CY INTERFERENCE PROTECTION Section for more information STACKING The PRO CUT 60 cannot be stacked TILTING The PRO CUT 60 must be placed on a stable level surface using the attached undercarriage so it will not topple over HIGH FREQUENCY INTERFERENCE PROTECTION Locating installing or maintaining the PRO CUT 60 incorrectly could cause interference with prop er radio TV or electronic equipmen...

Page 10: ... torch leads as short and as close together as possible a Lead length should not exceed 50 feet 15 2m b Tape leads together when possible 6 Check torch and work cable rubber insulation coverings to be sure they do not have any cracks or cuts that could result in high fre quency leakage that could interfere with other electronic equipment a Use insulated work cables with a high natural rubber conte...

Page 11: ...left side of the Input Box Assembly Access to the Input Box Assembly is at the top rear of the machine See your local and national electrical codes for proper grounding methods INPUT POWER SUPPLY CONNECTIONS A qualified electrician should connect the input power supply leads to the L1 and L2 terminals on the Input Box Assembly Terminal Block 1 Follow all national and local electrical codes 2 Follo...

Page 12: ...input port is a 1 4 6 3mm NPT thread b Connect the air supply to the machine reg ulator with an appropriate gas connection fitting Sealing the connection with Teflon tape is recommended 2 Tighten the air fitting connection to prevent leakage Do not overtighten NOTE When using nitrogen gas from a cylinder the cylinder must have a pressure regulator Maximum psi from nitrogen gas cylinder to PRO CUT ...

Page 13: ...____ To reconnect the machine to a different voltage change the position of the power straps links on the reconnect panel assembly Follow The Input Supply Connection Diagram located on the inside of the access door 1 For 208 230 460 VAC machines see Figure A 3a 2 For 460 575 VAC machines see Figure A 3b FIGURE A 3a Voltage Link Positions for 208 230 460 VAC machines FIGURE A 3b Voltage Link Positi...

Page 14: ...ne switch 2 Disconnect input power to the machine 3 Insert the torch cable into the machine through the cable boot 8 a Insert enough torch cable to make all connections 4 Turn and lock strain relief clamp 1 onto bolt to secure the gas line 5 Connect the gas line fitting to the brass union and tighten with a wrench 6 Connect to pilot lead 5 to terminal marked PILOT 7 Connect work lead 7 to terminal...

Page 15: ...ional Features and Controls B 2 Design Features and Advantages B 2 Cutting and Gouging Capability B 3 Limitations B 3 Controls and Settings B 3 Operating Steps B 4 Cutting Procedure Recommendations B 5 Pilot Arc B 5 Cutting and Gouging Recommendations B 5 Cutting Thin Metal B 6 Cutting Expanded Metal B 7 Cutting Thick Metal B 7 Gouging Metal B 8 TABLE OF CONTENTS OPERATION SECTION PRO CUT 60 Secti...

Page 16: ...st to remove fumes from breathing zone OPERATION PRO CUT 60 B 1 WELDING CUTTING and GOUGING SPARKS can cause fire or explosion Keep flammable material away Do not weld cut or gouge on containers that have held combustibles SAFETY PRECAUTIONS Read and understand entire section before operating machine Observe additional Safety Guidelines detailed in the beginning of this manual WARNING ARC RAYS can...

Page 17: ...include thin gage sheet metal and expanded metal OPERATIONAL FEATURES AND CONTROLS The PRO CUT 60 comes with an ON OFF POWER SWITCH OUTPUT CURRENT CON TROL and a RUN PURGE SWITCH DESIGN FEATURES AND ADVANTAGES The microprocessor controlled PRO CUT 60 design makes plasma cutting and gouging tasks uncomplicated This list of design features and advantages will help you understand the machine s total ...

Page 18: ...witch controls the air supply to the machine In the PURGE position air flows continuously through the torch to allow for the adjustment of air pres sure Note that the output is disabled in this mode In the RUN position air flows through the torch when the torch trigger is activated 3 STATUS LED DISPLAY The following machine conditions are displayed MACHINE ON LED The green POWER ON LED glows when ...

Page 19: ...ER ON LED glows The fan starts NOTE If the SAFETY LED glows press the SAFETY RESET button If there is no prob lem the SAFETY LED will go off If the SAFE TY LED remains on turn the ON OFF POWER SWITCH to OFF and refer to the TROUBLESHOOTING GUIDE in the TROU BLESHOOTING AND REPAIR SECTION of this manual for a recommended course of action 5 Set the PURGE RUN switch in the PURGE position The air flow...

Page 20: ...lasma arc cutting is a very eco nomical process when used properly Improper procedures or equipment use will result in poor quality work and high operating costs The follow ing procedures will help you get maximum perfor mance from your PRO CUT 60 Use Pilot Arc Properly The pilot arc transfers the arc to the work piece for cutting Do not start the pilot arc repeatedly over short periods of time Th...

Page 21: ...out put current ranges for the thickness of the metal being cut Cutting Thin Gauge Sheet Metal 1 Set the OUTPUT CURRENT CONTROL out put at mid range Yellow range or below 2 Pierce a hole in the metal surface to start the cut Then lightly touching the nozzle to the metal surface drag the torch along the cut line 3 Use the 035 0 8mm nozzle for fine cuts Larger nozzle sizes work better and provide lo...

Page 22: ...he OUTPUT ON and FAULT LEDs flash alternately Cutting Thick Sections of Metal 1 Set the OUTPUT CURRENT CONTROL above the mid range Red position a Use the minimum current needed to make a satisfactory cut 2 Hold the torch nozzle about 1 8 3 2mm from the cutting surface Do not let the torch nozzle touch the work or carry a long arc a Use the S24114 Drag Cup to protect the torch b Use only the 052 1 ...

Page 23: ...his process will blow a lot of molten metal and dross BE CAREFUL Blow the dross away from the torch away from the operator and away from flammable objects d Do not allow the torch cable or body to contact hot surfaces e Performance is similar to air carbon arc gouging with a 1 8 3 2mm carbon electrode FIGURE B 3 Gouging Metal OPERATION PRO CUT 60 B 8 ANGLE MAINTAINED THROUGHOUT GOUGE TORCH HELD AT...

Page 24: ...NOTES B 9 PRO CUT 60 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 25: ...Page Accessories Section C Accessories C 1 TABLE OF CONTENTS ACCESSORIES SECTION PRO CUT 60 Section C Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 26: ...RCH SPARE PARTS KIT K872 Included with each machine Includes Shield Cup Asmbly S24162 Nozzles 035 0 9mm Orifice S18497 1D 1 042 1 1mm Orifice S18497 2D 1 052 1 3mm Orifice S18497 3D 1 078 Gouging 2 0mm Orifice S18497 4D 1 Electrode S18752D 1 Drag Cup Asmbly S24114 Wrench S18808 Tool Box S19576 1 1 These parts come in a 5 pack ACCESSORIES PRO CUT 60 C 1 3 99 Return to Section TOC Return to Section ...

Page 27: ...s D 1 Capacitor Discharge Procedure D 1 D 2 Routine and Periodic Maintenance D 3 3 D Exploded View D 4 TABLE OF CONTENTS MAINTENANCE SECTION PRO CUT 60 Section D Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 28: ...e disconnect switch or fuse box before working on this equipment Failure to follow this capaci tor discharge procedure can result in electric shock Do not touch electrically hot parts CAPACITOR DISCHARGE PROCEDURE PROCEDURE DESCRIPTION This procedure must be performed before per forming any maintenance inside the machine MATERIALS NEEDED High resistance high wattage resistor 25 1000 ohms 25 watts ...

Page 29: ...on the insulated gloves 5 Grip the middle of the resistor with the insulated pliers 6 Touch the resistor leads across the two capacitor straps as shown for 10 seconds a DO NOT TOUCH THE CAPACITOR STRAPS WITH YOUR HANDS OR ANY OTHER PART OF YOUR BODY 7 Test for zero volts across the capacitor terminals with a DC voltmeter a Capacitor terminal polarity is marked on the capacitor straps b If any volt...

Page 30: ...is or materials that could block the air flow to the machine for cooling 3 Inspect the torch cable for any slits puncture marks in the cable jacket kinks or any condition that could restrict air flow to the torch Repair or replace when needed To avoid receiving a high frequency shock keep the torch and torch cables in good condition Perform the following every three months or sooner 1 Check air re...

Page 31: ...eturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC MAINTENANCE PRO CUT 60 D 4 CASE FRONT ASSEMBLY CASE BACK ASSEMBLY INPUT BOX ASSEMBLY CONTROL PANEL ASSEMBLY HIGH FREQUENCY BOARD ASSEMBLY BASE ASSEMBLY CAPACITOR BANK FIGURE D 2 General Assembly Exploded View ...

Page 32: ...NOTES D 5 PRO CUT 60 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 33: ... Transformer E 1 Output Rectification E 2 High Voltage High Frequency and By Pass Circuit E 3 Pilot Arc E 4 Transistor Switching Operation E 5 PWM Operation and Thermal Protection E 6 TABLE OF CONTENTS THEORY OF OPERATION SECTION PRO CUT 60 Section E Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 34: ... input voltage and current to the voltage and cur rent levels necessary for plasma cutting In addi tion the main transformer also has several isolated auxiliary windings 115vac 24vac and 12vac The 115vac winding supplies power for the cooling fan and powers the air solenoid the CR2 relay and the high voltage transformer via the control board One 24vac winding produces supply power for the control ...

Page 35: ...board compares the commands of the output control potentiometer with the shunt feedback signal and the appropriate pulse width modulated PWM control signal is sent to the power board The power board converts the PWM control signal into an isolated drive signal This isolated signal drives the transistor module to the optimum level to obtain the desired machine output current The control and power b...

Page 36: ...ary of the high volt age transformer delivers a high voltage to the spark gap generator and also to the high frequen cy transformer The high frequency transformer transfers the high frequency spark to the torch terminal This momentary burst of high fre quency is used to ignite the pilot arc The by pass board is necessary to prevent any unwanted signals from interfering with the Pro Cut 60 circuitr...

Page 37: ...flow is from the positive potential work terminal through the R2 resistor and CR2 contacts to the pilot lead circuit in the torch cable The pilot current transfers from the nozzle to the electrode in the torch head and then on to the torch bulkhead connector which is con nected to the negative potential within the machine When the torch head is brought close to the work piece the pilot arc transfe...

Page 38: ...gions of a transistor They are used at high frequencies in high power applications and switching circuits When used as a switch the transistor will be turned on collector current flow when there is adequate base drive current Likewise the device will be turned off no collector current when there is insufficient base drive current The tran sistor allows the control of a large amount of cur rent flo...

Page 39: ...rating If excessive operating temperature should occur the thermostat will dis able the machine output and the yellow thermal indicator light will glow The fan should remain on during this period Once the machine cools suffi ciently the thermostat will reset If the thermostat shutdown is caused by excessive output or duty cycle and the fan is operating normally the power switch may be left on and ...

Page 40: ...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 PRO CUT 60 E 7 NOTES ...

Page 41: ...nternal Trigger Safety Circuit Test F 15 F 20 Transistor Module Test F 21 F 23 Main Transformer Test F 24 F 26 Power Board Test F 27 F 30 High Voltage Transformer and Circuit Test F 31 F 33 Replacement Procedures On Off Power Switch Removal F 34 F 35 Control Board Removal F 36 F 37 Power Board Removal F 38 F 40 Transistor Module Removal F 41 F 42 SCR Module Removal F 43 F 45 Fan Blade and Fan Moto...

Page 42: ...ving the case wrap around cover Step 3 PERFORM COMPONENT TESTS The last column labeled Recommended Course of Action lists the most likely com ponents that may have failed in your machine It also specifies the appropriate test procedure to verify that the subject com ponent is either good or bad If there are a number of possible components check the components in the order listed to eliminate one p...

Page 43: ...uch electrically hot parts Remove the P C Board from the static shielding bag and place it directly into the equipment Don t set the P C Board on or near paper plastic or cloth which could have a sta tic charge If the P C Board can t be installed immediately put it back in the static shielding bag If the P C Board uses protective shorting jumpers don t remove them until installation is complete If...

Page 44: ...O CUT 60 Single Phase 3 Check the input line fuses Replace if blown RECOMMENDED COURSE OF ACTION 1 Make sure ON OFF Power Switch S1 is operating properly 2 Check the main transformer primary leads to the re connect panel for loose or faulty connections 3 Check the leads from the ON OFF Power Switch S1 to the reconnect panel T1 and T2 for loose or faulty connections 4 Perform Main Transformer Test ...

Page 45: ...MMENDED COURSE OF ACTION 1 Check plug J7 located on the Control Board and associated wires for loose or faulty connections 2 Check Plug J9 on Status Board and J8 on Control Board for loose or faulty connections 3 Test for 24 VAC between leads C2 and H6 plug J7 on Control Board Refer to wiring diagram a If the 24 VAC IS NOT present or voltage is very low the main transformer could be faulty Perform...

Page 46: ...y be faulty RECOMMENDED COURSE OF ACTION 1 If the high frequency spark is present at the spark gap located inside the panel the torch and cable assembly may be faulty Perform the Torch Torch Cable Assembly and Internal Trigger and Safety Circuit Tests 2 If the high frequency spark is not present at the spark gap check that pilot control relay CR2 contacts close when the torch trigger is pulled a I...

Page 47: ...bly may be faulty Perform Torch Torch Cable Assembly and Internal Trigger and Safety Circuit Tests If the high frequency spark is present at the spark gap for 1 second go to step 3 2 If the high frequency spark is not present at the spark gap check that the pilot control relay CR2 contacts close when the torch trigger is pulled a If pilot control relay CR2 contacts close when torch trig ger is pul...

Page 48: ...ch and cable assembly 1 Check Torch Consumables 2 Check for proper Air Pres sure 3 Check work cables and connections 4 Clean any painted or heavily corroded work surfaces 5 If no malfunction or fault indi cators are lit then contact your local Lincoln Authorized Field Service Facility RECOMMENDED COURSE OF ACTION 1 The normally closed primary thermostat could be faulty Replace See wiring diagram 2...

Page 49: ... MISADJUSTMENT S 1 The pilot arc duty cycle has been exceeded The machine should cool down and the lights quit blinking in 20 seconds The pilot arc duty cycle is limited to 20 out of 80 seconds except in spe cial circumstances such as cutting expanded metal RECOMMENDED COURSE OF ACTION Make sure operator is not exceeding pilot arc duty cycle If for any reason you do not understand the test procedu...

Page 50: ...et for 60 65 PSI Turn power off then restart machine RECOMMENDED COURSE OF ACTION 1 Remove leads 38 and 31 plug J12 from air solenoid SV1 Refer to wiring diagram a If air continues to flow the solenoid is faulty Replace b If the airflow stops when the solenoid SV1 leads are removed then the Control Board could be faulty 1 The Control Board could be faulty Replace If for any reason you do not under...

Page 51: ...he air solenoid by switching the machine to PURGE If the air pressure is sufficient the air should begin to flow and AIR PRESSURE LED should turn on Return to the RUN mode If air does not flow when the torch trig ger pulled consult your local Lincoln Authorized Field Service Facility 4 Check torch consumables replace if necessary RECOMMENDED COURSE OF ACTION 1 With 60 PSI applied to the machine th...

Page 52: ...andle Release the torch trigger and resume cutting or gouging 2 Check torch consumables for wear replace if neces sary 1 Make sure work cable and clamp are secure 2 Clean any painted or heavily corroded work surfaces RECOMMENDED COURSE OF ACTION 1 The torch and cable assembly could be faulty Perform the Torch Torch Cable Assembly and Internal Trigger and Safety Circuit Tests 2 Check Pilot Resistor...

Page 53: ...PHASE J6 J7 J10 8J5 7J5 6J5 5J5 4J5 6J10 J4 J2 J8 J5 L7941 POWER BOARD J22 1J22 2J22 1J20 4J22 2J20 3J22 4J20 40 NEG C C LEADS NEG LEAD H1 LEAD H1 H2 H2 LEAD 40 LEADS J20 G1 G2 B 40 J21 1J21 MOUNTING SCREWS CONTROL BOARD CONNECTOR LOCATION TROUBLESHOOTING REPAIR PRO CUT 60 F 12 FIGURE F 1 Control Board Connector Locations POWER BOARD CONNECTOR LOCATION FIGURE F 2 Power Board Connector Locations ...

Page 54: ...rs Insulated gloves DC Volt Ohm meter Multimeter TROUBLESHOOTING REPAIR PRO CUT 60 F 13 Service and repair should be performed only by Lincoln Electric factory trained per sonnel Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all ...

Page 55: ...e the two capacitors shown in Figure F 19 4 Put on the insulated gloves 5 Grip the middle of the resistor with the insulated pliers 6 Touch the resistor leads across the two capacitor straps as shown for 10 seconds a DO NOT TOUCH THE CAPACITOR STRAPS WITH YOUR HANDS OR ANY OTHER PART OF YOUR BODY 7 Test for zero volts across the capacitor terminals with a DC volt meter a Capacitor terminal polarit...

Page 56: ...d wrench TROUBLESHOOTING REPAIR PRO CUT 60 F 15 Service and repair should be performed only by Lincoln Electric factory trained per sonnel Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and pre cautions detailed t...

Page 57: ...ad com partment See Figure F 3 a Locate the torch cable access door on the Right Case Side Assembly of the machine b Remove the one sheet metal screw on the left hand side of the access door and swing open the door c Test for a voltage across the stud marked WORK and the bulkhead connector brass fitting NO voltage should be present If a voltage is present STOP DO NOT perform this test Contact the ...

Page 58: ...ief clamp out of the machine through the rubber boot 5 Move the torch cable assembly to a convenient work area 6 Perform the following resistance tests using a volt ohm meter Multimeter See Figures F 4 and F 5 for Torch and Cable Resistance Tests Points and Circuit Diagram a Test for resistance on 4 pin connector of 1 ohm or less continuity from pins 1 to 3 pin 3 to the pilot lead pilot lead to th...

Page 59: ...trol Board See Figure F 6 and Figure F 1 for the location of the Control Board and Plug J5 7 Locate the 4 pin recepta cle See Figure F 6 for location 3J10 6J5 5J5 24 VAC 24 VAC 3J5 2 BLUE NOZZLE ELECTRODE ELECTRODE PILOT CONE SWITCH SAFETY WIRE N C THERMOSTAT GUN TRIGGER TORCH HEAD CONDUCTOR IN GAS TUBE 4 PURPLE 336 RED 337 WHITE Pin 2 Pin 4 Pin 1 Pin 3 7J5 C1 3L 335 4J5 6J10 8J5 TORCH TORCH CABLE...

Page 60: ...onnect Plug J5 back into its header 11 Test for 24 VAC between Pin 5J5 lead C1 and Pin 7J5 lead 335 on Plug J5 a Carefully insert the volt ohm Multimeter probes into the back of the J5 plug into pin cavity 5J5 lead C1 and pin cavity 7J5 lead 335 See Figure F 1 b Connect input power to PRO CUT 60 c Turn ON OFF Power Switch to ON d Read meter If 24 VAC is NOT present continue with test procedure 12 ...

Page 61: ...r TOC G2015 PRO CUT 60 SINGLE PHASE J6 J7 J10 J4 J2 J8 2 4 1 3 8J5 3J5 REMOVE J5 PLUG 6J5 4J5 J5 4 PIN RECEPTACLE IN BULKHEAD TROUBLESHOOTING REPAIR PRO CUT 60 F 20 TORCH TORCH CABLE ASSEMBLY INTERNAL TRIGGER AND SAFETY CIRCUIT TEST CONTROL PC BOARD 4 PIN RECEPTACLE FIGURE F 6 Control Board and 4 pin Locations FIGURE F 7 Control Board and 4 Pin Connector Test Points ...

Page 62: ...ormed only by Lincoln Electric factory trained per sonnel Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and pre cautions detailed throughout this manual If for any reason you do not understand the test procedures...

Page 63: ... Module is mounted behind the Power Board and the terminal screw completes the electrical connection 7 Locate and remove the one lead marked NEG by removing the terminal screw connecting it to the Power Board See Figure F 9 a Move the lead out of the way 8 Replace the terminal screw snugly a little more than finger tight The Transistor Module is mounted behind the Power Board and the terminal scre...

Page 64: ...ght The Transistor Module is mounted behind the Power Board and the terminal screw completes the electrical connection 11 Perform the following resi tance tests listed in Table F 1 NOTE Meter lead polarity must be observed for these resistance tests a If a low resistance is measured in both polarities the transistor module is shorted Replace the transis tor module the Power Board and the Control B...

Page 65: ...Multimeter PRO CUT 60 Wiring Diagrams Service and repair should be performed only by Lincoln Electric factory trained per sonnel Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and pre cautions detailed throughout ...

Page 66: ...te on the Power Board leads H1 and H2 to the SCR module See Figure F 2 2 Turn ON OFF Power Switch to ON 3 Test for 190 VAC across leads H1 and H2 4 Turn ON OFF Power Switch to OFF Test B Auxiliary Winding Tests 1 Perform the four Auxiliary Winding Tests in Table F 2 Turn the ON OFF Power Switch to ON for each test Turn the ON OFF Power Switch to OFF between each test When testing a lead connected ...

Page 67: ... to Master TOC Return to Master TOC TROUBLESHOOTING REPAIR PRO CUT 60 F 26 MAIN TRANSFORMER TEST CONTROL PC BOARD POWER PC BOARD CONTROL RELAY CR2 FIGURE F 10 Main Transformer Test Components L1 METER PROBE LEAD 31 TOUCH METER PROBE TO LEAD 31 CONNECTED TO THE COIL OF THE CONTACTOR L2 CR2 L3 FIGURE F 10A CR2 Lead Locations for Table F 2 ...

Page 68: ...ment PRO CUT 60 Wiring Diagrams Service and repair should be performed only by Lincoln Electric factory trained per sonnel Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and pre cautions detailed throughout this m...

Page 69: ...achine 2 Turn ON OFF Power Switch to OFF Test A Test for 12 VAC voltage to Power Board 1 Locate and insert probes into Power Board Plug locations 1J22 lead H4 and 3J22 lead H3 See Figure F 11 Carefully insert the probes into the lead cavity to make contact with the lead 2 Turn ON OFF Power Switch to ON a If 12 VAC is NOT present check Plug J22 for loose or faulty wiring b If no loose or faulty wir...

Page 70: ...er Switch to OFF a If 7 VDC is NOT present check Power Board Plug J22 and Control Board Plug J6 for loose or faulty wiring b If no loose or faulty wiring is found the Power Board or the Control Board could be faulty Replace Test C Test for 1 0 VDC to 1 5 VDC Base Voltage to Transistor Module NOTE This test requires that the torch trigger be pulled to activate the circuit Be sure to use an isolated...

Page 71: ...y 2 Turn the ON OFF Power Switch to ON 3 Pull torch trigger When air pre flow times out and the pilot arc is established 0 2 VDC to 0 3 VDC should be present 4 Release torch trigger 5 Locate and insert probes into the following Power Board plug locations See Figure F 11 a Insert the NEGATIVE probe into Plug 1J21 lead 383 lead cavity b Insert the POSITIVE probe into Plug 4J20 lead G1 lead cavity 2 ...

Page 72: ...meter only PRO CUT 60 Wiring Diagrams Service and repair should be performed only by Lincoln Electric factory trained per sonnel Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and pre cautions detailed throughout ...

Page 73: ...chine 2 Turn ON OFF Power Switch to OFF Test A Test for 115 VAC primary voltage to High Frequency Transformer 1 Locate and connect probes to leads 35 and 31 on Control Relay CR2 Use alligator clips for best results See Figure F 12 2 Turn ON OFF Power Switch to ON 3 Pull the torch trigger to close Control Relay CR2 contacts 115 VAC will be present for only ONE SECOND when the torch trigger is pulle...

Page 74: ...istance of High Voltage Transformer Secondary 1 Perform Test B Steps 1 2 3 if needed 2 Locate the two white leads soldered into the two black doughnut chokes located below the High Frequency Transformer See Figure F 12 3 Touch the probes to the two white leads Resistance should be about 12 500 ohms a If approximately 12 500 ohms is not measured replace the High Voltage Transformer Test D Test Chok...

Page 75: ...ice and repair should be performed only by Lincoln Electric factory trained per sonnel Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and pre cautions detailed throughout this manual If for any reason you do not u...

Page 76: ...enter of the knob Remove from the shaft See Figure F 13 5 Remove the face plate by squeezing the two tabs together and sliding the plate off See Figure F 13 6 Loosen the four screws on the plastic frame These screws go through the Case Front Assembly into the line switch When the screws no longer engage the line switch remove the line switch so it can be worked on 7 Remove and save the electrical ...

Page 77: ...placement Control Board Service and repair should be performed only by Lincoln Electric factory trained per sonnel Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and pre cautions detailed throughout this manual If...

Page 78: ...ne 2 Remove the Left Case Side assembly 3 Perform the CAPACITOR DISCHARGE PROCEDURE 4 Remove the seven Molex plugs from their headers and position out of the way See Figure F 1 5 Remove the 10 mounting screws 6 Remove the Control Board from the machine by carefully lifting it straight up until clear of all other parts 7 Insert the replacement Control Board carefully into the machine and install in...

Page 79: ...trap Replacement Power Board Service and repair should be performed only by Lincoln Electric factory trained per sonnel Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and pre cautions detailed throughout this manu...

Page 80: ...L REPLACEMENT PROCEDURE 1 Disconnect input power to the machine 2 Remove the Left Case Side Assembly 3 Perform the CAPACITOR DISCHARGE PROCEDURE 4 Remove the Molex Plugs J20 J21 and J22 from the Power Board 5 Remove G1 G2 40 B lead spade lugs from the terminals on the SCR modules See Figure F 14 6 Remove the two C leads the NEG lead and the two 40 leads by unscrewing the terminal screws with a Phi...

Page 81: ... so the Power Board position can be adjusted when installing the mounting and terminal screws 13 Install the four mounting screws finger tight 14 Connect leads H1 and H2 to the SCR modules with the terminal screws finger tight 15 Connect leads C two wires NEG and 40 two wires with the terminal screws finger tight 16 Tighten the six screws connect ing the Power Board to the SCR modules to 35 in lbs...

Page 82: ...Lincoln T12837 or equivalent Dow Corning 340 Replacement Power Board Service and repair should be performed only by Lincoln Electric factory trained per sonnel Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and pr...

Page 83: ...le a Clean the heat sink surface with 000 fine steel wool b Rinse the heat sink surface with alcohol or acetone c Apply a 002 to 005 coat of joint compound evenly to the heat sink mounting surface and the Transistor Module mounting surface Use Lincoln Joint Compound T12837 or equivalent such as Dow Corning 340 d Press the Transistor Module onto the heat sink surface Remove the module to make sure ...

Page 84: ...d Lincoln T12837 or equivalent Dow Corning 340 Service and repair should be performed only by Lincoln Electric factory trained per sonnel Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and pre cautions detailed th...

Page 85: ...ide assembly 3 Perform the CAPACITOR DISCHARGE PROCEDURE 4 Perform the POWER BOARD REMOVAL PROCEDURE 5 Remove the two socket head cap screws of the top SCR module using a 4mm Allen type wrench 6 Remove the SCR module from the heat sink 7 Remove the second SCR mod ule following Steps 5 and 6 8 Install the replacement SCR Modules Procedure is the same for both SCR modules a Clean the heat sink surfa...

Page 86: ... surface Use Lincoln Joint Compound T12837 or equivalent such as Dow Corning 340 d Press the SCR Module onto the heat sink surface Remove the module to make sure enough joint compound has been applied When removed both surfaces should have an even texture with no bare spots If this even textured look does not appear re apply the joint compound e Mount the SCR Module on the heat sink with the 4mm s...

Page 87: ...tric factory trained per sonnel Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and pre cautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform ...

Page 88: ...er supply leads from the terminal block 6 Remove the six screws from the Case Back Assembly There are two screws at the top and four at the bottom After the last screw is removed be prepared to use a strap or other support to keep the Case Back Assembly from falling open The motor leads could be pulled out of their con nectors if this should happen 7 Unscrew the brass air line con nector from the ...

Page 89: ...tor shaft NOTE See Step 13 when reinstalling the fan 11 Remove the fan motor a Loosen and remove the two nuts flat washers and lock washers from the motor mounting bracket using an 11 32 open end wrench When the motor is free from the mounting bracket place it carefully on the bottom of the machine b Remove the Case Back Assembly c Cut the wire wraps bundling the motor leads d Cut the motor leads ...

Page 90: ... wrench supplied with the machine Service and repair should be performed only by Lincoln Electric factory trained per sonnel Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and pre cautions detailed throughout this...

Page 91: ...om the bulkhead compartment a Locate the torch cable access door on the Right Case Side Assembly of the machine b Remove the one sheet metal screw on the left hand side of the access door and swing open the door c Test for a voltage across the stud marked WORK and the bulkhead connector brass fitting NO voltage should be present If a voltage is present STOP Perform Capacitor Discharge Test again I...

Page 92: ...in relief clamp out of the machine through the rubber boot 4 Move the torch cable assembly to a convenient work area 5 Remove the three Phillips head screws holding the torch handle together 6 Unplug the red and white safety leads in the torch head 7 Remove the tape and insulation carefully Save the tape and insulation to re apply during assembly The insulation is extremely important because of th...

Page 93: ...n 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 VOLTS HERTZ 208 60 230 60 460 60 575 60 MAXIMUM IDLE AMPS 4 4 4 0 2 0 1 6 Output Control at Minimum 26 Amps 43VDC Output Control at Maximum 60 Amps 90VDC Return to Section TOC Return to Section TOC Retu...

Page 94: ...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 F 53 NOTES PRO CUT 60 ...

Page 95: ...41 G 8 Status Board Components M15601 G 10 Bypass Board Components M15603 G 12 Bypass Board Components M17322 G 14 Wiring Diagram Codes 10112 10118 G 16 Wiring Diagram Codes 9819 10096 G 17 Control Board Schematic G2015 G 18 Power Board Schematic L7941 G 19 TABLE OF CONTENTS ELECTRICAL DIAGRAMS PRO CUT 60 Section G Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC...

Page 96: ...8 6 4 8 P R O C U T 6 0 S T A T U S B O A R D S C H E M A T I C NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is provided for reference only Lincoln Electric dis courages board level...

Page 97: ...J 3 2 0 V 1 6 0 J T P 2 7 1 P O S 3 8 8 8 S 1 8 6 4 9 B Y P A S S P C B D S C H E M A T I C NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is provided for reference only Lincoln Elect...

Page 98: ... for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is provided for reference only Lincoln Electric dis courages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the M...

Page 99: ...NOTES PRO CUT 60 G 5 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 100: ...responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is provided for reference only Lincoln Electric dis courages board level troubleshooting and repair since it may compromise the quality of the design and may result in d...

Page 101: ...1 R40 R41 R43 R44 R81 R82 R94 R95 R96 R97 R98 R103 R104 R111 R123 R130 R150 R151 R152 R165 R170 R171 R172 R173 R140 R142 R143 RESISTOR MF 1 4W 100K 1 R144 RESISTOR MF 1 4W 1 00M R76 RESISTOR MF 1 4W 10 0 1 R46 R90 R93 RESISTOR MF 1 4W 1 50K 1 R55 R62 R66 RESISTOR MF 1 4W 200 1 R30 R45 R57 R59 R69 R83 RESISTOR MF 1 4W 2 21K 1 R157 R158 R174 R101 R137 RESISTOR MF 1 4W 22 1K 1 R70 R89 R91 R100 R139 R...

Page 102: ...ity for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is provided for reference only Lincoln Electric dis courages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to th...

Page 103: ...DZ3 ZENER DIODE 1W 6 2V 5 1N4735A Q2 Q3 TRANSISTOR NMF T220 3 5A 60V IRF513 D3 D4 D5 D6 DIODE AXLDS 3A 600V 1N5406 R1 R9 RESISTOR CC 2W 120 5 TP1 MOV 320VRMS 160J 20MM R4 R21 R23 RESISTOR MF 1 4W 1 00K 1 R3 RESISTOR MF 1 4W 10 0K 1 R22 RESISTOR MF 1 4W 150 1 R5 R6 RESISTOR MF 1 4W 2 00K 1 R19 R20 RESISTOR MF 1 4W 20 0 1 R8 RESISTOR MF 1 4W 26 7 1 R2 R7 RESISTOR MF 1 4W 4 75K 1 R17 RESISTOR MF 1 4W...

Page 104: ...tric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is provided for reference only Lincoln Electric dis courages board level troubleshooting and repair since it may compromise the quality of the design and...

Page 105: ...HLMP 3400 CONNECTOR 8 PIN MOLEX CONNECTOR NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is provided for reference only Lincoln Electric dis courages board level troubleshooting and r...

Page 106: ...sumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is provided for reference only Lincoln Electric dis courages board level troubleshooting and repair since it may compromise the quality of the design and may re...

Page 107: ...60J MOV NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is provided for reference only Lincoln Electric dis courages board level troubleshooting and repair since it may compromise the ...

Page 108: ...ssumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is provided for reference only Lincoln Electric dis courages board level troubleshooting and repair since it may compromise the quality of the design and may r...

Page 109: ...C4 C5 047 1600 10 CAPACITOR NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is provided for reference only Lincoln Electric dis courages board level troubleshooting and repair since it...

Page 110: ...2 4 J 1 2 1 J 1 2 3 4 2 2 2 2 2 1 J 6 J 1 2 R 5 L 5 0 3 L 5 0 4 N A P I L O T L E A D A T T H E T O R C H N O T E S N U M B E R 3 I S C O N N E C T E D T O T H E N O Z Z L E H3 H4 H6 MAIN SEC J 2 J 1 0 J 2 1 L 1 2 1 5 4 1 T 1 T 2 L 1 1 2 1 4 5 T 1 T 2 T O G R O U N D P E R N A T I O N A L E L E C T R I C A L C O D E T O P R I M A R Y C O I L S S 1 T S 1 T O S U P P L Y L I N E S L 2 2 3 L 1 1 2 1 ...

Page 111: ...T R I C A L C O D E T O P R I M A R Y C O I L S S 1 T S 1 T O S U P P L Y L I N E S L 2 2 3 L 1 1 2 1 4 5 T 1 T 2 6 8 7 3 3 5 3 2 3 1 3 7 C 1 C 2 H 6 5 1 0 3 8 6 3 8 3 3 8 4 7 2 8 3 3 2 3 3 8 3 8 5 3 1 3 2 H 4 3 3 2 3 3 8 C2 31 C E N T E R B O T T O M 2 6 3 1 7 4 8 P R I T O P 5 1 0 0 W 3 8 9 C 3 0 0 W 4 0 5 0 W 3 9 1 C R 2 7 1 3 7 2 5K 5 W N B 2 0 8 V S I N G L E M A C H I N E S O N L Y 2 0 8 V C...

Page 112: ...138 D 5 G N D IN O U T X 2 5 W 17V D Z 7 D 9 5 m H L 3 5 m H L 4 D 7 3 3 0 0 5 0 V C 3 5 0 V 27 C 5 8 4 7 3 5 V C 4 5 W 15V D Z 8 5 V 5 V 18B 18A 6 81K R 5 D P 6 J 6 3 CNY17 3 OCI7 4 5 6 10K R 9 6 4 7 3 5 V C 4 3 D 3 6 D71 221K R 1 5 6 100V 100p C 4 5 1 50K R 9 0 10K R 9 5 100 R 1 2 8 10K R 9 4 221K R 9 1 1 50K R 9 3 1 2 OF 2 4 CNY17 3 OCI6 4 5 6 10K R 1 1 1 15 V 15 V C 15 V 0 2mH P T 3 1 2 1W 3 3...

Page 113: ...le from Lincoln Electric This information is provided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine Return to Section TOC Return to Section TOC Return to Section TOC Return to Sectio...

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