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PRO-CUT 80

Summary of Contents for PRO-CUT 80

Page 1: ...E OR REPAIR THIS EQUIPMENT WITHOUT READ ING THIS MANUAL AND THE SAFETY PRECAUTIONS CON TAINED THROUGHOUT And most importantly think before you act and be careful SERVICE MANUAL For use with machine co...

Page 2: ...PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you pur chase...

Page 3: ...od electrical earth ground 3 f Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation 3 g Never dip the electrode in wat...

Page 4: ...revent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydrauli...

Page 5: ...on inflamma bles 4 Des gouttes de laiter en fusion sont mises de l arc de soudage Se prot ger avec es v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons san...

Page 6: ...ral Description B 3 Recommended Processes and 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...

Page 7: ...elect 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 Connection A 5 Input Power Cord Connector...

Page 8: ...60 81 80 460 1 60 48 80 Three Phase Input Input Currents Rated Output Amps Voltage and Hertz 208 3 60 48 80 230 3 60 44 80 460 3 60 25 80 IDLE CURRENT AND WATTS IDLE CURRENT AND WATTS 230 1 60 0 61 Am...

Page 9: ...Code Ambient Temperature 30 C or Less AC Input Voltage Fuse Super Lag Type 75 C at Circuit Breaker Copper Wire in Conduit AWG 60 Hertz Delay Type IEC Sizes 230VAC Single Phase 100 Amps 4 21 1mm2 4 21...

Page 10: ...NG FALLING EQUIPMENT can cause injury Do not use the pull handle on the optional undercarriage if installed to lift the machine This handle is not designed to support the full weight of the machine Us...

Page 11: ...CONNECTOR INSTALLATION The PRO CUT 80 is supplied with one 11 foot 3 35m 8 AWG 3 lead input power cord already connected to the machine A cord connector provides a strain relief for the input power co...

Page 12: ...also included on the inside of the door 2 For 230 Position the large switch to 200 230 See Figure A 2 For 460 Position the large switch to 380 460 See Figure A 2 3 Move the A lead to the appr opriate...

Page 13: ...ss through the 1 4 in 6 4mm NPT input port on the filter body CYLINDER could explode if damaged Keep cylinder upright and chained to a fixed support Keep cylinder away from areas where it could be dam...

Page 14: ...ON The PRO CUT 80 is supplied from the factory with a PCT 80 cutting torch Additional cutting torches can be ordered from the K1571 series Hand held and mechanized torches come with 25 or 50 foot cabl...

Page 15: ...ting Capability B 4 Consumable Life B 4 Limitations B 4 Controls and Settings B 5 Pilot Arc Considerations B 5 Cutting Operation B 5 Safety Status Indicator B 6 User Responsibility B 7 Preheat Tempera...

Page 16: ...dangerous Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone CUTTING SPARKS can cause fire or explosion Keep flammable material away Do not cut containers that...

Page 17: ...o 85 amps These applications include thin gage sheet metal and expanded metal OPERATIONAL FEATURES AND CONTROLS The PRO CUT 80 comes with an ON OFF POWER SWITCH OUTPUT CURRENT CONTROL PURGE BUTTON STA...

Page 18: ...trode under normal operating conditions is approximately 160 starts cuts An erosion of 060 in 1 5mm is typ ical for end of electrode life However the electrode may last longer A green and erratic arc...

Page 19: ...n the pilot arc is started a slight impulse will be felt in the torch handle This occurrence is normal and is the mechanism which starts the plasma arc This impulse can also be used to help troublesho...

Page 20: ...g arc Keep moving while cutting Cut at a steady speed without pausing Maintain the cutting speed so that the arc lag is 10 to 20 behind the travel direction Use a 5 15 leading angle in the direction o...

Page 21: ...plate thickness preheat quench gas type gas flow rate and equipment may produce results different from those expected Some adjustments to proce dures may be necessary to compensate for unique individu...

Page 22: ...ctrode to rub against the inside bottom surface of the nozzle This will help remove any oxide buildup Replace the nozzle turn on the power and continue cutting If the Parts in Place circuit safety sta...

Page 23: ...accessed through pins I and J of the 14 pin MS connector The circuit provides a dry contact closure when the arc has transferred Input to this cir cuit should be limited to 0 3 A for either 120VAC or...

Page 24: ...NOTES B 10 B 10 PRO CUT 80...

Page 25: ...TABLE OF CONTENTS ACCESSORIES Accessories Section C Options Accessories C 2 Section C 1 Section C 1 PRO CUT 80...

Page 26: ...hields the torch tip and provides more visibility to the workpiece than the drag cup Note the shield cup does not prevent the torch tip from touching the workpiece S22151 Drag Cup The drag cup protect...

Page 27: ...n D 1 PRO CUT 80 TABLE OF CONTENTS MAINTENANCE Maintenance Section D Safety Precautions D 2 Input Filter Capacitor Discharge Procedure D 2 Routine Maintenance D 3 Periodic Maintenance D 3 Major Compon...

Page 28: ...m This resis tor is not supplied with machine NEVER USE A SHORTING STRAP FOR THIS PROCEDURE 5 Locate the two capacitor terminals large hex head cap screws at the bottom of the Power Board shown in Fig...

Page 29: ...riodically and relieve any so as not to restrict the flow of air to the torch PERIODIC MAINTENANCE ELECTRIC SHOCK can kill Turn off machine at the disconnect switch on the front of the machine before...

Page 30: ...4 3 5 1 2 Maintenance D 4 D 4 PRO CUT 80 FIGURE D 2 MAJOR COMPONENT LOCA TIONS 1 Case Front 2 Base and Case Back 3 Center Panel Assembly 4 Output Board Heatsink 5 Power Board Assembly 6 Case Wraparoun...

Page 31: ...IFIER FAN MOTOR 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 D Y A I R L O W T H E R M A L S A F E Y T...

Page 32: ...ltage and also connect the auxiliary trans former for the appropriate input voltage The auxiliary transformer develops the appropriate AC voltages to operate the cooling fan the control board and the...

Page 33: ...oltage If either should occur the appropriate signal is sent to the con trol board to deactivate the CR1 CR2 input relay The machine output will also be disabled THEORY OF OPERATION E 3 E 3 PRO CUT 80...

Page 34: ...GBT pairs induce an AC square wave output signal at the secondary of the main transformer The DC current flow through each primary winding is redirected or clamped back to each respective filter capac...

Page 35: ...oling A portion of the cooling air exits the chamber through vents in the side of the nozzle A swirl texture located inside the bottom of the nozzle increases the plenum air swirl strength and improve...

Page 36: ...erating conditions to the user THEORY OF OPERATION E 6 E 6 PRO CUT 80 FIGURE E 6 CONTROL AND DISPLA Y BOARDS INPUT LINE SWITCH INPUT RECTIFIER FAN MOTOR A L E A D AUXILIARY TRANSFORMER OUTPUT CONTROL...

Page 37: ...CTION Two thermostats protect the machine from excessive operating temperatures One thermostat is located on the output choke and the other on the power board IGBT heat sink Excessive temperatures may...

Page 38: ...T in an active mode When the gate signal a positive DC voltage relative to the source is applied to the gate terminal of the IGBT it is capable of conducting current A voltage supply connected to the...

Page 39: ...1 conducting for 1 microsecond The negative portion is the other IGBT group1 The dwell time off time is 48 microseconds both IGBT groups off Since only 2 microseconds of the 50 microsecond time period...

Page 40: ...NOTES E 10 E 10 PRO CUT 80...

Page 41: ...Output Power Board Resistance Test F 20 Torch Continuity and Solenoid Test F 23 Air Gas Solenoid Test F 25 T2 Auxiliary Transformer Test F 27 Trigger Circuit Test F 30 Low Voltage Circuit Test F 35 R...

Page 42: ...ribute to the machine symptom Perform these tests checks in the order listed In general these tests can be con ducted without removing the case wrap around cover Step 3 PERFORM COMPONENT TESTS The las...

Page 43: ...it directly into the equipment Don t set the PC Board on or near paper plastic or cloth which could have a static charge If the PC Board can t be installed immediately put it back in the static shield...

Page 44: ...n 2 Check the input voltage at the machine Input voltage must match the rating plate and the reconnect panel 3 Check for blown or missing fuses in the input lines and the 0 6 amp slow blow reconnect f...

Page 45: ...eplace The machine powers up properly but there is no response when the gun trigger is pulled Only the power LED is lit 1 Make sure the torch is connect ed properly to the PRO CUT 80 machine 2 Make su...

Page 46: ...Make sure the air pressure is set at 70 psi 448 kPa 2 Make sure the torch consum ables are in place and in good condition 3 Make sure the air flow is not restricted 1 Perform the Torch Continuity and...

Page 47: ...the operating proce dure is correct for the process See the Operation section of this manual 2 Make sure the work clamp is connected tightly to the work piece 3 The workpiece must be electri cally con...

Page 48: ...s off not flow ing 1 The pressure switch S5 or associated leads may be faulty See the Wiring Diagram 2 The control board may be faulty Replace The Safety LED is flashing 1 Make sure there is a Lincoln...

Page 49: ...1 800 833 9353 PROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENT S RECOMMENDED COURSE OF ACTION LED FUNCTION PROBLEMS The Thermal LED is lit 1 One of the machine s ther mostats has tripped Do not tur...

Page 50: ...the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 W...

Page 51: ...G STRAP FOR THIS PROCEDURE 5 Locate the four capacitor terminals large hex head cap screws shown in Figure F 1 At the bottom of thePowerBoard 203 206 207 202 6 Use electrically insulated gloves and in...

Page 52: ...se 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 Lin...

Page 53: ...rlier in this section 3 Locate the input rectifier D1 and lead loca tions See Figure F 2 Carefully remove the silicone sealant from leads 207 207A and 209 4 With the phillips head screw driver remove...

Page 54: ...g of Essex D 4 8 insulating com pound and Dow Corning 738 Silicone Sealant 8 If the input rectifier is faulty see the Input Rectifier Bridge Removal Replacement procedure See the Wiring Diagram and Fi...

Page 55: ...any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before...

Page 56: ...205 208 TEST PROCEDURE 1 Remove main input power to the PRO CUT 80 2 Perform the Input Filter Capacitor Discharge Procedure detailed earlier in this section 3 Locate the primary power board and asso...

Page 57: ...ms 203A 208 Less than 100 ohms 206 208 Greater than 1000 ohms 208 206 Less than 100 ohms 206 205 Greater than 1000 ohms 205 206 Less than 100 ohms TABLE F 2 PRIMARY POWER BOARD RESISTANCE TEST POINTS...

Page 58: ...ed earlier in this section 3 Locate and familiarize yourself with the capacitor test locations on the primary power board See Figure F 3 4 The following tests will be performed with the input power ap...

Page 59: ...able F 3 the capaci tors or other components on the power board may be faulty Replace NOTE If the capacitor voltages are NOT bal anced within 20 VDC the capacitors may need conditioning See the Mainte...

Page 60: ...precautions detailed throughout this manu al If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Departme...

Page 61: ...er Capacitor Discharge Procedure detailed earlier in this section 3 Remove the torch assembly from the machine 4 Carefully remove leads X4 X2 B21 X20 X40 and plugs J33 and J32 from the output power bo...

Page 62: ...ssociated trace Probe Terminal X2 Diode A1 Greater than to and 1000 ohms Probe J33 Pin4 associated trace Probe J33 Pin4 Diode A1 Less than to and 100 ohms Probe Terminal X4 associated trace Probe Term...

Page 63: ...d throughout this manu al If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical tr...

Page 64: ...ulty Replace FIGURE F 5 TORCH CONNECTOR MACHINE END 1 2 3 4 5 6 7 8 9 TABLE F 5 TORCH ASSEMBLY RESISTANCES TEST CIRCUIT S BEING EXPECTED TEST POINTS TESTED RESISTANCE CONDITIONS Pin 7 to Pin 8 Paralle...

Page 65: ...detailed throughout this manu al If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for elect...

Page 66: ...zero or very low resistance of leads 366 and 361 between the solenoid and plug J31 See the Wiring Diagram If the leads are good the solenoid coil may be faulty 6 Carefully apply the 12 VDC supply to...

Page 67: ...If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance...

Page 68: ...4 Locate and disconnect plugs J21 and J22 from the wiring harness Cut any necessary cable ties See Figure F 8 5 Carefully apply the 230 VAC isolated supply to leads H1 located at the D1 input bridge...

Page 69: ...ck the harness wiring to the auxiliary transformer See the Wiring Diagram 10 When finished with the test replace plugs 21 and 22 and the case wraparound TROUBLESHOOTING REPAIR F 29 F 29 PRO CUT 80 T2...

Page 70: ...anu al If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assi...

Page 71: ...le receptacle Perform the Torch Continuity and Solenoid Test 5 If less than one ohm is read only when the torch trigger is pulled proceed to the next step Also see Output Board LED Definitions and rel...

Page 72: ...vate the torch trigger and remove input power to the PRO CUT 80 10 Perform the Input Filter Capacitor Discharge Procedure 11 Check the continuity of leads 354 and 312 between the output board and the...

Page 73: ...river circuits incorporated on the output board LED3 Green This light indicates that the air solenoid driver circuit is functioning When this LED is lit the air solenoid should be activated LED4 Green...

Page 74: ...This voltage is derived from the 15 VDC supply The 5 5 VDC supply is used to power the circuitry on the control board LED3 Red This light indicates that 18 VAC is being supplied to the control board f...

Page 75: ...are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION These v...

Page 76: ...t Board LED Definitions and Figure F 12 Low Voltage Circuit Diagram b To verify the presence of 32 VDC check across capacitor C13 Make certain the voltmeter probes make good contact with the capacitor...

Page 77: ...to remove the display board to check it a 15 VDC should be present at leads 216 to 219 See Figure F 15 and Figure F 12 Low Voltage Circuit Diagram 10 If any of the DC supply voltages are incorrect or...

Page 78: ...driver circuits incorporated on the output board LED3 Green This light indicates that the air solenoid driver circuit is functioning When this LED is lit the air solenoid should be activated LED4 Gre...

Page 79: ...ates that the 5 5 VDC is present This voltage is derived from the 15 VDC supply The 5 5 VDC supply is used to power the circuitry on the control board LED3 Red This light indicates that 18 VAC is bein...

Page 80: ...utions detailed throughout this manu al If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for...

Page 81: ...nut driver remove the four screws holding the front assembly to the top and base of the machine See Figure F 16 4 Carefully slide do not force the front away from the rest of the machine about one inc...

Page 82: ...mage to the equipment 8 When replacing the control board align the mounting holes with the eight mounting pins and gently slide the P C board onto the mounting pins until the board snaps onto the pins...

Page 83: ...cautions detailed throughout this manu al If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department f...

Page 84: ...led earlier in this section 3 Using the 5 16 nut driver remove the four screws holding the front assembly to the top and base of the machine See Figure F 19 4 Carefully slide do not force the front aw...

Page 85: ...rd carefully connect the plug into the board Make cer tain the plug is secure and the locking tab is in place 9 Align the display board with the three mounting pins and slide the display board into pl...

Page 86: ...n you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proce...

Page 87: ...EMENT continued PROCEDURE 1 Remove input power to the PRO CUT 80 machine 2 Remove the case wraparound and perform the Input Capacitor Filter Discharge Procedure detailed earlier in this section 3 Loca...

Page 88: ...2 J33 and J34 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 four screws from the lower upper left and right corne...

Page 89: ...re to do so can result in permanent damage to the equipment 2 Mount the output power board to the heat sink and pre torque the four socket head screws to 25 inch pounds 3 Finish tightening the four sc...

Page 90: ...do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Cal...

Page 91: ...ine 2 Remove the case wraparound and perform the Input Filter Capacitor Discharge Procedure detailed earlier in this section 3 Locate the primary power board and associ ated lead and plug connections...

Page 92: ...e primary power board See Figure F 24 8 Using the 3 16 allen type wrench remove the eight socket head screws and lock wash ers mounting the primary power board to the heat sink 9 Carefully remove the...

Page 93: ...of Penetrox A 13 Electrical Joint Compound to the mating sur faces of the P C board and the heat sink and capacitor terminals 5 Mount the P C board to the heat sink and capacitor assembly Make sure t...

Page 94: ...erstand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 83...

Page 95: ...or Discharge Procedure detailed earlier in this section 3 Locate the input rectifier and the leads con nected to it See Figure F 25 4 Identify and mark the leads connected to the rectifier terminals 5...

Page 96: ...netrox A 13 Heat Sink Compound Lincoln E2529 to the mating surfaces Torque the mounting cap screws and nuts to 44 in lbs 9 Reconnect the 10 leads to the correct ter minals and torque the phillips head...

Page 97: ...removal of any mechanical part that could affect the machine s electrical characteristics or if any electrical components are repaired or replaced the machine must be retested INPUT IDLE AMPS AND WATT...

Page 98: ...NOTES F 58 F 58 PRO CUT 80...

Page 99: ...IRING DIAGRAM G 2 CONTROL PC BOARD SCHEMATIC G 3 CONTROL PC BOARD ASSEMBLY CODE 10574 G 4 CONTROL PC BOARD ASSEMBLY CODE 10577 10578 G 5 POWER PC BOARD SCHEMATIC G 6 POWER PC BOARD ASSEMBLY G 7 OUTPUT...

Page 100: ...ITORS ARE A MATCHED SET H2 J2 4 J3 T1 J5 J22 J34 4 1 4 503 6 3 CURRENT VIEWED FROM COMPONENT SIDE OF BOARD A 277B 7 209 CONTROL 302 9 S3 PSI_SET 4 J1 J20 J33 J2 J21 J31 LEFT SIDE OF MACHINE 277 DISPLA...

Page 101: ...92K R194 3 32K R28 1 30K R82 33 2K R21 5 11K R85 D23 LT1014 221K R83 100K R80 47 50V C4 COM 15V COM COM COM COM COM COM COM COM COM 10 0K R27 10 0K R84 243 R37 243 R33 C35 50V 0 1 C16 15V COM COM COM...

Page 102: ...24073 1 10K 1 2W TRIMMER R19 R53 R55 R57 R85 R149 7 S19400 5111 5 11K 1 4W R157 R20 R22 R110 R111 R124 12 S19400 10R0 10 1 4W R125 R126 R127 R128 R142 R196 R197 R24 R35 2 S19400 2210 221 1 4W R25 R47...

Page 103: ...S19400 5110 511 1 4W R11 R12 R13 R14 4 S19400 3320 332 1 4W R16 R21 2 S19400 3322 33 2K 1 4W R17 R23 R26 R27 R61 R62 31 S19400 1002 10K 1 4W R63 R68 R69 R81 R84 R93 R94 R104 R106 R108 R134 R138 R139...

Page 104: ...DZ12 1 00K R65 1W 15V DZ1 1W 15V DZ13 1W 6 2V DZ11 1 00K R67 10 0 R63 C3 C1 E2 E4 C2 E3 G2 C4 E1 A4 G4 G3 G1 10 0 R68 2000V 022 C24 2000V 022 C12 S4 G4 FROM S1 G3 G1 S2 G2 TEST B S3 PRIMARY 1A 1000V D...

Page 105: ...27 1 S19400 1000 100 1 4W R28 R36 R38 R44 R47 R87 10 S19400 2213 221K 1 4W R88 R96 R118 R119 R29 R30 R31 R32 R73 R74 12 T14648 19 1K 5W R75 R76 R77 R78 R80 R81 R35 1 S19400 3162 31 6K 1 4W R39 R46 R49...

Page 106: ...K R59 D21 1W 12V DZ11 D15 1W 12V DZ12 5W 15V DZ3 D19 D20 3 32K R22 D9 2V on board EACH REMOTE on board on board Labeled X2 P3 EACH Labeled X4 FEEDBACK VOLTAGE WORK EACH P2 26 26 on board Labeled X40 N...

Page 107: ...Q5 1 T12704 68 2N4401 Q6 1 T12704 86 TRANSISTOR IGBT 1200V 45A R1 R38 2 T12300 47 15 W 200 OHM RESISTOR R2 1 S19400 5110 511 1 4W R3 R4 2 T12300 66 15W 56 OHM PWR RESISTOR R5 1 T14648 2 25 5W R6 R8 R...

Page 108: ...HLMP 2655 DIODES NOTES ELECTRICAL SYMBOLS PER E1537 1A 400V RESISTORS Ohms CAPACITORS GENERAL INFORMATION UNLESS OTHERWISE SPECIFIED UNLESS OTHERWISE SPECIFIED NUMBER WITHOUT AFFECTING THE INTERCHANG...

Page 109: ...R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 DZ1 C5 C1 C2 C3 C4 DISPLAY L10721 1 LED2 LED8 LED9 LED5 LED6 LED7 LED4 LED3 LED1 Q1 Q4 Q2 Q3 0 0 4 30 4 00 1 10 1 00 20 1 40 C1 C2 C3 C4 C...

Page 110: ...___________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ____...

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