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SVM146-A
September, 1999
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper installation
. . . and thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READING THIS MANUAL AND THE
SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And,
most importantly, think before
you act and be careful.
SERVICE MANUAL
For use with machine code numbers 10573, 10574, 10577, 10578
PRO-CUT ™80
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• 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 •
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SAFETY
i i
PRO-CUT 80
FOR ENGINE
powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b.Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
____________________________________________________
1.c. Do not add the fuel near an open flame weld-
ing 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 filling tank. If fuel is spilled,
wipe it up and do not start engine until fumes
have been eliminated.
____________________________________________________
1.d. Keep all equipment safety guards, cov ers and
devices in position and in good repair.Keep
hands, hair, clothing and tools away from Vbelts, gears, fans and all other moving parts
when starting, operating or repairing equipment.
____________________________________________________
1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
___________________________________________________
1.f. Do not put your hands near the engine fan. Do not attempt to
override the governor or idler by pushing on the throttle control rods while the engine is running.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following saf ety highlights.F or additional safety information, it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding 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
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
WARNING
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1.
Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. Do not work next to welding power source.
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer, birth defects, and other reproductive harm.
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
The Above For Diesel Engines
The Above For Gasoline Engines
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SAFETY
ii ii
PRO-CUT 80
ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
ELECTRIC SHOCK can kill.
3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good 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 water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
FUMES AND GASES
can be dangerous.
5.a.Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
5.b.
Do not weld in locations near chlorinated hydrocarbon
vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
to
form phosgene, a highly toxic gas, and other irritating
products.
5.c. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
5.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.e. Also see item 1.b.
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SAFETY
iii iii
PRO-CUT 80
FOR ELECTRICALLY
powered equipment.
8.a.Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
CYLINDER may explode
if damaged.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
•Away from areas where they may be struck or subjected to
physical damage.
•A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot”parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
WELDING SPARKS can
cause fire or explosion.
6.a.
Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
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
hydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact can
cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even
though
they have
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Preparation
for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding.They may explode.
6.f.
Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits.
This can create fire hazards or overheat lifting chains or
cables until they fail.
6.h. Also see item 1.c.
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SAFETY
iv iv
PRO-CUT 80
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suivantes:
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours tout contact entre les parties sous tension et la
peau nue ou les vétements mouillés. Porter des gants
secs et sans trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand
on soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement
dans les positions assis ou couché pour lesquelles une
grande partie du corps peut être en contact avec la
masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
d. Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous ten-
sion des porte-électrodes connectés à deux machines à
souder parce que la tension entre les deux pinces peut
être le total de la tension à vide des deux machines.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enroule le câble-électrode autour de n’importe quelle partie
du corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du
rayonnement de l’arc et des projections quand on soude
ou quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnementde
l’arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laiter en fusion sont émises de l’arc de
soudage. Se protéger avec es vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pantalons 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 l’on pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir ttout risque d’incendie dû étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé
de la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de la faire. Si on place
la masse sur la charpente de la construction ou d’autres
endroits éloignés de la zone de travail, on augmente le
risque de voir passer le courant de soudage par les chaines
de levage, câbles de grue, ou atres circuits. Cela peut
provoquer des risques d’incendie ou d’echauffement des
chaines et des câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumées toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opéerations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les
vapeurs du solvant pour produire du phosgéne (gas fortement roxique) ou autres produits irritants.
PRÉCAUTIONS DE SÛRETÉ POUR LES
MACHINES À SOUDER À TRANSFORMATEUR ET À REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code
de l’électricité et aux recommendations du fabricant. Le dispositif de montage ou la piece à souder doit être branché à
une bonne mise à la terre.
2. Autant que possible, l’installation et l’entretien du poste
seront effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la
debrancher à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispostifis de sûreté à leur
place.
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MASTER TABLE OF CONTENTS FOR ALL SECTIONS
v v
PRO-CUT 80
Page
Safety.................................................................................................................................................i-iv
Installation.............................................................................................................................Section A
Technical Specifications ..........................................................................................................A-2/3
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
Input Power Cord Connector Installation ...................................................................................A-5
Frame Grounding........................................................................................................................A-5
Gas Input Connections ...............................................................................................................A-7
Output Connections....................................................................................................................A-8
Operation...............................................................................................................................Section B
Safety Precautions......................................................................................................................B-2
General 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 and Settings.................................................................................................................B-5
Pilot Arc Discussion....................................................................................................................B-5
Cutting Operation .......................................................................................................................B-5
User Responsibility.....................................................................................................................B-7
Preheat Temperature for Plasma Cutting ...................................................................................B-7
Procedure Recommendations....................................................................................................B-7
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-4
Test Procedures ........................................................................................................................F-10
Replacement Procedures .........................................................................................................F-40
Electrical Diagrams..............................................................................................................Section G
Parts Manual....................................................................................................................P-340 Series
RETURN TO MAIN INDEX
Page 7
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TABLE OF CONTENTS
- INSTALLATION SECTION -
Section A-1 Section A-1
PRO-CUT 80
Installation
Technical Specifications .............................................................................................................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 Connection ..............................................................................................................A-5
Input Power Cord Connector Installation...................................................................................A-5
Input Wire and Fuse Size .....................................................................................................A-5
Reconnect Procedure...........................................................................................................A-6
Gas Input Connections...............................................................................................................A-7
Output Connections ...................................................................................................................A-8
Torch Connection .................................................................................................................A-8
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INSTALLATION
A-2 A-2
PRO-CUT 80
TECHNICAL SPECIFICATIONS - PRO-CUT 80
INPUT RATINGS
Single Phase Input Input Currents Rated Output Amps
Voltage and Hertz
208/1/60 87 80
230/1/60 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 Amps 140 Watts
RATED OUTPUT
Duty Cycle Rated Output Amps
60% 80
100% 60
OUTPUT
Current Range Open Circuit Voltage Pilot Current
35 - 85 Amps 335VDC Maximum 20 Amps @ 100%
Duty Cycle
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INSTALLATION
A-3 A-3
PRO-CUT 80
TECHNICAL SPECIFICATIONS (Cont’d) - PRO-CUT 80
GAS REQUIREMENTS
Required Gas Flow Rate Required Gas Inlet Pressure
70 PSI @ 480 SCHF 80 to 150 PSI
(4.8 Bar. @ 13550 LHR) (5.4 Bar. to 10.2 Bar.)
RECOMMENDED INPUT WIRE AND FUSE 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
60 Hertz (Delay Type) (IEC) Sizes
230VAC Single Phase 100 Amps #4 (21.1mm2) #4 (21.1mm2)
460VAC Single Phase 60 Amps #8 (8.4mm2) #8 (8.4mm2)
230VAC Three Phase 60 Amps #8 (8.4mm2) #8 (8.4mm2)
460VAC Three Phase 40 Amps #10 (5.3mm2) #10 (5.3mm2)
PHYSICAL DIMENSIONS
Height Width Depth Weight with
Torch Cable
16.5 Inches 13.75 Inches 29.5 Inches 98 lbs. (44.5 kg.)
419 mm 349 mm 749 mm (25 ft. cable)
113 lbs. (51.4 kg.)
(50 ft. cable)
Page 10
Read this entire installation section before you
start installation.
SAFETY PRECAUTIONS
ELECTRIC SHOCK can kill.
• Turn the input power OFF at the
disconnect switch or fuse box
and discharge input capacitors
before working inside the equipment.
• Do not touch electrically hot parts or electrodes with
your skin or wet clothing.
• Always connect the 80 grounding terminal (located
on the side of the Case Back Assembly) to a good
electrical earth ground.
• Always wear dry, insulating gloves.
• Turn the 80 Power Switch OFF when connecting
power cord to input power.
Only qualified personnel should install, use, or service this equipment.
SELECT SUITABLE LOCATION
Place the PRO-CUT 80 where clean cool air can freely
circulate in through the rear louvers and out through
the front/bottom opening. Dirt, dust or any foreign
material that can be drawn into the machine should be
kept at a minimum. Failure to observe these precautions can result in excessive operating temperatures
and nuisance shutdown of the machine.
A source of clean, dry air or nitrogen must be supplied
to the PRO-CUT 80. Oil in the air is a severe problem
and must be avoided. The supply pressure must be
between 80 and 150 psi.The flow rate is approximately 6.0 cfm (170 l/min.). Failure to observe these precautions could result in excessive operating temperatures or damage to the torch.
STACKING
The PRO-CUT 80 cannot be stacked.
LIFTING AND MOVING
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. Using it to
lift the machine could cause personal injury or damage to the
machine.
• Either the front or rear handles or both may be used
to lift or move the machine.
TILTING
The PRO-CUT 80 must be placed on a stable, level
surface so it will not topple over.
HIGH FREQUENCY INTERFERENCE
PROTECTION
The PRO-CUT 80 employs a touch start mechanism
for arc initiation. This eliminates high frequency emissions from the machine as compared with spark gap
and solid state type high frequency generators. Keep
in mind, though, that these machines may be used in
an environment where other high frequency generating
machines are operating. By taking the following steps,
you can minimize high frequency interference.
• Make sure the power supply chassis is connected to
a good earth ground. The work terminal ground does
NOT ground the machine frame.
• Keep the work ground clamp isolated from other w ork
clamps that have high frequency.
• If the ground clamp cannot be isolated, then keep the
clamp as far as possible from other work clamp connections.
• When the machine is enclosed in a metal building,
several good earth driven electrical grounds around
the periphery of the building are recommended.
Failure to observe these recommended installation procedures may cause improper function of the Pro-Cut or
possibly even damage the control system or power
supply components.
INSTALLATION
A-4 A-4
PRO-CUT 80
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WARNING
WARNING
Page 11
INPUT CONNECTIONS
ELECTRIC SHOCK can kill.
• Have a qualified electrician install and
service this equipment.
• Turn the input power off at the fuse box
before working on this equipment.
• Do not touch electrically hot parts.
Before installing the machine, check that input supply
voltage, phase, and frequency are the same as the
machine’s voltage, phase, and frequency as specified
on the machine’s rating plate. See Figure A.1.
The PRO-CUT 80 should be connected only by a qualified electrician. Installation should be made in accordance with the U.S. National Electrical Code, all local
codes, and the information detailed below.
GROUND CONNECTION
The frame of the PRO-CUT 80 must be properly grounded.
A ground terminal marked with the symbol is
mounted on the case bottom directly behind the input
power switch for this purpose. The ground lead of the
input power cord that is attached to the machine must
be connected to this ground terminal. See the
National Electric Code for details on proper grounding
methods. Install in accordance with all local and
national electrical codes.
INPUT POWER CORD CONNECTOR
INSTALLATION
The PRO-CUT 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 cord as it passes through the left
rear access hole. The cord connector is designed for
a cord diameter of .40 - 1.03 in (10.2 - 26.2mm) if it
becomes necessary to install a different input cord.
See Figure A.1.
For three phase connection: Replace the input power
cord with a #10 AWG 4 lead cable.
Connect the leads of the cable to a fused power panel.
Make sure the green lead is connected to the panel
and the panel is connected to a good earth ground.
Install in accordance with all local and national electric
codes.
INPUT WIRE AND FUSE SIZE
Fuse the input circuit with the super lag fuses or delay
type circuit breakers recommended on the Technical
Specifications page. Choose an input and grounding
wire size according to local or national codes; also see
the Technical Specifications page. Using fuses or
circuit breakers smaller than recommended may result
in “nuisance” shut-offs from inrush currents, even if
you are not cutting at high currents.
INSTALLATION
A-5 A-5
PRO-CUT 80
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FIGURE A.1 – RATING PLATE LOCATION
1
2
3
WARNING
1. CASE BACK
2. RATING PLATE
3. POWER CORD CONNECTOR WITH STRAIN RELIEF
Page 12
RECONNECT PROCEDURE
When received directly from the factory, the machines
are internally connected for 230 VAC. Reconnection
will be necessary if a higher input voltage is used. To
reconnect the Pro-Cut to 460 VAC or to connect back
to 230 VAC, follow the directions as outlined below.
Follow this procedure ONLY while the Pro-Cut is dis-
connected from the input power.
Failure to follow these instructions can cause immediate failure of components in the welder.
1. Open the access door on the side of the machine.
Connection instructions are also included on the
inside of the door.
2. For 230: Position the large switch to 200-230. See
Figure A.2.
For 460: Position the large switch to 380-460. See
Figure A-2.
3. Move the “A” lead to the appropriate terminal.
FIGURE A.2 – RECONNECTION DIAGRAM
INSTALLATION
A-6 A-6
PRO-CUT 80
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CAUTION
VOLTAGE = 380 - 460V
VOLTAGE = 200 - 230V
RECONNECT PROCEDURE
ELECTRIC
SHOCK
CAN KILL
• Disconnect input power before
inspecting or servicing machine.
• Do not operate with wraparound
removed.
• Do not touch electrically live parts.
• Only qualified persons should install,
use, or service this equipment.
WARNING
1. BE SURE POWER SWITCH IS OFF.
2. CONNECT LEAD 'A' TO DESIRED INPUT VOLTAGE RANGE.
440 - 460V
380 - 415V
220 - 230V
200 - 208V
3. POSITION SWITCH TO DESIRED INPUT VOLTAGE RANGE.
'A'
Page 13
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INSTALLATION
A-7 A-7
PRO-CUT 80
GAS INPUT CONNECTIONS
Supply the PRO-CUT 80 with clean compressed air or
nitrogen.
• Supply pressure must be between 80 psi and 150
psi.
• Flow rate should be approximately 6.0 cfm (170
I/min.).
NOTE: Oil in the air supply to the PRO-CUT 80 can
cause severe problems. Use only a clean air
supply.
• Connect the gas supply to the PRO-CUT 80’s
pneumatic nipple at the air filter. See Figure A.3.
• Compressed gas should be supplied to the fitting
connection mounted on the filter at the rear of the
machine. If necessary, this fitting can be removed
allowing plumbing access through the 1/4 in.
(6.4mm) NPT input port on the filter body.
CYLINDER could explode if damaged.
• Keep cylinder upright and chained to a fixed suppor t.
• Keep cylinder away from areas
where it could be damaged.
• Never lift machine with cylinder
attached.
• Never allow the cutting torch to
touch the cylinder.
• Keep cylinder away from live electrical parts.
• Maximum inlet pressure 150 psi.
NOTE: When using nitrogen gas from a cylinder, the
cylinder must have a pressure regulator.
• Maximum psi from nitrogen gas cylinder to PROCUT 80 regulator should never exceed 150 psi.
• Install a hose between the nitrogen gas cylinder
regulator and the PRO-CUT 80 gas inlet.
FIGURE A.3 - COMPRESSED GAS CONNECTION
1. CASE BACK
2. PNEUMATIC NIPPLE
3. AIR FILTER
4. FLEX TUBE (TO REGULATOR INSIDE MACHINE)
WARNING
1
2
3
4
Page 14
XXXXXXXX XXXXXXXX XXXXXXXX XXXXXXXX
PRO-CUT 80
Torch
Connector
Work
Cable
Input
Power
Switch
Output
Control
Knob
Consumable
Storage
(behind
door)
Status
Indicators
Reset
Button
Gas
Purge
Button
Gas
Regulator
Gauge
Gas
Regulator
Knob
Interface
Connector
OUTPUT CONNECTIONS
TORCH CONNECTION
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 cables.
All torches are connected to the Pro-Cut with a quick
connect at the case front for easy change over. See
Figure A-4.
For more information on the torch and its components,
refer to the PCT 80 Operator’s Manual (IM595).
FIGURE A.4 - TORCH CONNECTION
AT CASE FRONT
INSTALLATION
A-8 A-8
PRO-CUT 80
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Page 15
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Section B-1 Section B-1
PRO-CUT 80
TABLE OF CONTENTS
- OPERATION SECTION -
Operation...............................................................................................................................Section B
Safety Instructions ......................................................................................................................B-2
General Description ....................................................................................................................B-3
Recommended Process 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 and Settings.................................................................................................................B-5
Pilot Arc Considerations .............................................................................................................B-5
Cutting Operation .......................................................................................................................B-5
Safety Status Indicator ..............................................................................................................B-6
User Responsibility .....................................................................................................................B-7
Preheat Temperature for Plasma Cutting ...................................................................................B-7
Procedure Recommendations....................................................................................................B-7
General .................................................................................................................................B-7
Thin Gauge Sheet Metal ......................................................................................................B-7
Thick Sections of Metal........................................................................................................B-8
Suggestions for Extra Utility From the Pro-Cut System......................................................B-8
Machine Interface........................................................................................................................B-9
Arc Start.......................................................................................................................................B-9
Arc Initiated.................................................................................................................................B-9
Arc Voltage..................................................................................................................................B-9
Page 16
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B-2
B-2
PRO-CUT 80
OPERATING INSTRUCTIONS
Read and understand this entire section of operating
instructions before operating the machine.
SAFETY INSTRUCTIONS
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrodes with your skin or wet clothing.
• Insulate yourself 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 SPARKS can cause
fire or explosion.
• Keep flammable material away.
• Do not cut containers that have held combustibles.
ARC RAYS can burn.
• Wear eye, ear, and body protection.
PLASMA ARC can injure.
• Keep your body away from nozzle and
plasma arc.
• Operate the pilot arc with caution. The
pilot arc is capable of burning the operator, others, or even piercing safety
clothing.
Observe additional Safety Guidelines detailed in
the beginning of this manual.
WARNING
OPERATION
Page 17
GENERAL DESCRIPTION
The PRO-CUT 80 is an inverter based constant current, continuous control plasma cutting power source.
It provides superior and reliable starting characteristics, cutting visibility and arc stability. When cutting
expanded metal, the PRO-CUT 80 out-performs the
competition due to its quick, clean response to arc
transfers. The power supply design provides high
transfer-to-cut distances, which makes pierce cutting
more reliable with less nozzle wear. The control system
has a safety mechanism to insure that the nozzle and
electrode are in place before cutting or gouging. This
is extremely important due to the high voltages
involved.
The PRO-CUT 80 comes standard with an air regulator, coarse air filter, and pressure gauge. There are six
different torch and cable systems to choose from:
hand-held torch with 25’ or 50’ cable, machine and
robotic torch both with 25’ and 50’ cable.
Consumables are included so that cutting can begin
right out of the box. Consumables can also be
ordered as individual packages.
The PRO-CUT 80 initiates the plasma arc with a simple, yet reliable, touch-start mechanism. This system
eliminates many of the failure problems associated
with hi-frequency start systems. The PRO-CUT 80 is
capable of cutting with nitrogen or air.
The PRO-CUT 80 is controlled by a microprocessorbased control board. The machine performs rudimentary self troubleshooting when powered up, which aids
in field servicing.
RECOMMENDED PROCESSES AND
EQUIPMENT
The PRO-CUT 80 is capable of all cutting and gouging
applications within its output capacity of 35 to 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, STATUS INDICATORS and a SAFETY
RESET BUTTON. See Figure B.2 and related discussion.
DESIGN FEATURES AND
ADVANTAGES
The microprocessor controlled PRO-CUT 80 design
makes plasma cutting and gouging tasks uncomplicated. This list of design features and advantages will
help you understand the machine's total capabilities
so that you can get maximum use from your machine.
• Light weight and portable design for industrial use.
• Continuous control, 35 - 85 amps.
• Reliable touch start mechanism for plasma arc initiation.
• Unique microprocessor controlled starting
sequence for safe and consistent starting.
• Rapid arc transfer for fast cutting of expanded
metal.
• High transfer distance for ease of use.
• Input overvoltage protection.
• 3.0 second pilot arc.
• Purge momentary push button.
• Air regulator and pressure gauge located on the
front of machine for convenience.
• ”Parts-in-Place” mechanism to detect proper installation of consumables and torch.
• Automatic detection of faulty output control.
• In-line coarse air filter.
• Preflow/Postflow timing. Preflow is eliminated if arc
is re-initiated in Postflow.
• Thermostatic Protection.
• Solid state overcurrent protection.
• Works with pure nitrogen for cutting nonferrous
materials.
• Reconnectable for multiple input voltages.
• Quick disconnect torch.
• Display indicators for machine status.
• Unique electrode and Vortech™ nozzle design for
optimum cooling and long life.
• Swirl texture inside Vortech™ nozzle for better starting reliability and higher quality cuts.
• Unique drag cup design for durability and elimination of double arcing.
OPERATION
B-3 B-3
PRO-CUT 80
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Page 18
CUTTING CAPABILITY
The PRO-CUT 80 is rated at 80 amps, at 60% duty
cycle on a 10 minute basis or 60 amps, at 100% duty
cycle. If the duty cycle is exceeded, a thermal protector will shut off the output of the machine until it cools
to the normal operating temperature.
Figure B.1 shows the cut capacity of the PRO-CUT 80
when cutting mild steel. The graph plots cut thickness
vs. torch travel speed with a torch standoff of 0.15 in.
(3.8mm).
Example: 0.5 material
Amps Speed (IPM)
55 25
80 35
FIGURE B.1 – LINCOLN’S PRO-CUT 80 MILD STEEL CUT CAPACITY CHART
CONSUMABLE LIFE
The expected life for the PRO-CUT 80's electrode
under normal operating conditions is approximately
160 starts/cuts. An erosion of .060 in. (1.5mm) is typical for end of electrode life. However, the electrode
may last longer. A green and erratic arc will indicate
definite electrode failure, and the electrode should be
replaced immediately.
It is recommended that consumables be replaced in
complete sets. (Example: Electrode and Nozzle). This
will maximize the performance of the PRO-CUT 80
system.
LIMITATIONS
Do not exceed output current and duty cycle rating of
machine. Do not use the PRO-CUT 80 for pipe thawing.
OPERATION
B-4 B-4
PRO-CUT 80
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Lincoln's PRO-CUT 80
Mild Steel Cut Capacity Chart
100
80
60
40
80% of Maximum Speed
20
25 A
Recommended Torch Travel Speed (IPM)
0
0.000 0.125 0.250
0.375 0.500 0.625 0.750
Material Thickness
35 A
55 A
80 A
1.00
Page 19
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OPERATION
B-5 B-5
PRO-CUT 80
CONTROLS AND SETTINGS
FIGURE B.2 - CASE FRONT CONTROLS
OUTPUT CURRENT CONTROL KNOB - Adjusts the
amount of cutting current applied. Affects cutting
speed, dross formation, cut width, heat zone and travel speed.
TORCH CONNECTOR - Quick- connect type coupling
for the PCT 80 cutting torch.
WORK CABLE - Provides clamp and cable connection
to workpiece.
ON/OFF POWER SWITCH - Turns machine on or off.
GAS REGULATOR KNOB - Adjusts compressed gas
pressure delivered to the torch. Length of torch hose
is an adjustment factor. Optimum setting is 70-75 psi.
The gas purge button must be pressed in to set pressure.
GAS REGULATOR GUAGE - Provides gas presssure
reading as set by the gas regulator knob.
GAS PURGE BUTTON - Used to check or set gas
pressure. Push in and hold to check pressure, then
continue to hold to set the pressure. Shuts off gas
when released.
RESET BUTTON - Used to reset the machine following
a safety circuit trip.
STATUS (DISPLAY) BOARD INDICATORS - Four lights
indicating Power, Gas Low, Thermal and Safety.
PILOT ARC CONSIDERATIONS
The Pro-Cut has a smooth, continuous pilot arc. The
pilot arc is only a means of transferring the arc to the
workpiece for cutting. Repeated pilot arc starts, in
rapid succession, is not recommended as these starts
will generally reduce consumable life.
Occasionally, the pilot arc may sputter or start intermittently. This is aggravated when the consumables
are worn or the air pressure is too high. Always keep
in mind that the pilot arc is designed to transfer the arc
to the workpiece and not for numerous starts without
cutting.
When the pilot arc is started, a slight impulse will be
felt in the torch handle. This occurrence is normal and
is the mechanism which starts the plasma arc. This
impulse can also be used to help troubleshoot a "no
start" condition.
CUTTING OPERATION
When preparing to cut or gouge, position the machine
as close to the work as possible. Make sure you have
all materials needed to complete the job and have
taken all safety precautions. It is important to follow
these operating steps each time you use the machine.
• Turn the machine's ON/OFF POWER SWITCH to
the OFF position.
• Connect the air supply to the machine.
• Turn the main power and the machine power switch
on.
- The fan should start.
- The pre-charge circuit will operate for 3 seconds,
then the green "Power" status indicator should
turn on.
- If the "SAFETY" status indicator is lit, push the
"Reset" button. If there is no problem, the status
indicator will go off. If there is a problem, refer to
"STATUS INDICATOR" in this section.
• Be sure that the work lead is clamped to the workpiece before cutting.
• Set the output current control knob for maximum
current for high cutting speed and less dross formation per Figure B.1. Reduce the current, if desired,
to reduce the kerf (cut) width, heat affected zone or
travel speed as required.
• Push-in and hold the Purge button to check or set
the gas pressure. Pull the pressure regulator cap out
and turn it to set the pressure.
- Adjust the gas regulator for 70 PSI for 25 foot
(7.62m) torches or 75 PSI for 50 foot (15.24m)
torches.
- Release the Purge button.
XXXXXXXX XXXXXXXX XXXXXXXX XXXXXXXX
PRO-CUT 80
Torch
Connector
Work
Cable
Input
Power
Switch
Output
Control
Knob
Consumable
Storage
(behind
door)
Status
Indicators
Reset
Button
Gas
Purge
Button
Gas
Regulator
Gauge
Gas
Regulator
Knob
Interface
Connector
Page 20
- The gas will immediately turn off. The pressure
gauge may show an increase in pressure after the air
turns off, but this is normal. Do NOT reset the pressure while the air is NOT flowing.
• When ready to cut, place the torch near the work,
make certain all safety precautions have been taken
and pull the trigger.
- The air will flow for a preflow time of 2 seconds
and the pilot arc will start. (This is true unless the
machine is in postflow, then the preflow time is
skipped and the pilot arc will start immediately.)
- The pilot arc will run for 3 seconds and shut off
unless the arc is brought in contact with the work
and the arc is transferred. Avoid excessive pilot
arc time by transferring the arc to the workpiece
quickly to improve parts life.
- When the arc is brought within 1/4 in. (6.4mm)
from the workpiece the arc will transfer, the current will ramp up to the setting on the control
panel, and the cut can last indefinitely (or until the
duty cycle of the Pro-Cut is exceeded). Do not
touch the nozzle to the work when cutting.
Damage to the consumables may result.
• Pierce the workpiece by slowly lowering the torch
onto the metal at a 30° angle away from the operator. This will blow the dross away from the torch tip.
Slowly rotate the torch to vertical position as the arc
becomes deeper.
• Hold the nozzle standoff 1/8 in. (3.2mm) to 3/16 in.
(4.7mm) above the workpiece during cutting. Do not
let the torch nozzle touch the work or carry a long
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 of the cut.
• Use the drag cup to maintain constant standoff for
better cut quality and to protect the nozzle from
spatter.
• Use the drag cup with a metal template to prevent
nozzle double arcing.
• Finish the cut to be made and release the trigger.
• When the trigger is released, the arc will stop.
- The gas will continue to flow for 10 seconds of
postflow. If the trigger is activated within this time
period, the pilot arc will immediately restart.
• If the dross is difficult to remove, reduce the cutting
speed. High speed dross is more difficult to remove
than low speed dross.
• The right side of the cut is more square than the left
as viewed along the direction of travel.
• Clean spatter and scale from the nozzle and drag
cup frequently.
• For gouging, tilt the torch about 45° from the work-
piece and hold the nozzle 1/8 in. (3.2mm) to 3/16”
(4.7mm) above the workpiece.
SAFETY STATUS INDICATOR
• If the "SAFETY" status indicators light at any time,
check the following:
- Check the assembly of the torch consumables. If
they are not properly in place, the machine will not
start. Make sure that the shield cup is hand
tight. Do not use pliers or overtighten.
OPERATION
B-6 B-6
PRO-CUT 80
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Direction of Travel
5° - 15°
10° - 20°
Arc Lag
Leading Angle
00
3030
0
90
CUT
TORCH AT 300ANGLE
VERVERTICAL ANGLETICAL ANGLE
FOR CUTTINGFOR CUTTING
TO PIERCE
ROTATE TO
0
ANGLE TO CUT
90
ANGLE
OF APPROACH
TORCH HELD AT
0
45
ANGLE
THROUGHOUT GOUGE
ANGLE
MAINTAINED
THROUGHOUT
GOUGE
Page 21
ELECTRIC SHOCK can kill.
• Turn off machine at the disconnect switch on the front of the
machine before tightening,
cleaning or replacing consumables.
- Check the conditions of the inside of the nozzle. If
debris has collected, rub the electrode on the
inside bottom of the nozzle to remove any oxide
layer that may have built up. Refer to
“Suggestions for Extra Utility from the Pro-Cut
System.”
-
Check the condition of the electrode. If the end has
a crater-like appearance, replace it along with the
nozzle. The maximum wear depth of the electrode
is approximately .062 in. (1.6mm). A green and
erratic arc will indicate definite electrode failure.
The electrode should be replaced immediately.
• Replace the nozzle when the orifice exit is eroded
away or oval shaped.
• After the problem is found, or if there is nothing
apparently wrong, reset the machine by pressing
the "Reset" button. (It is possible for electrical noise
to trip the safety circuit on rare occasions. This
should not be a regular occurrence.)
• If the machine does not reset or continues to trip,
consult the Troubleshooting Section.
• Use the proper cutting or gouging procedures
referred to in “Procedure Recommendations”
below.
USER RESPONSIBILITY
Because design, fabrication, erection, and cutting variables affect results, the serviceability of a product or
structure is the responsibility of the user. Variation
such as plate chemistry, plate surface condition (oil,
scale), plate thickness, preheat, quench, gas type, gas
flow rate and equipment may produce results different
from those expected. Some adjustments to procedures may be necessary to compensate for unique
individual conditions. Test all procedures duplicating
actual field conditions.
PREHEAT TEMPERATURE FOR
PLASMA CUTTING
Preheat temperature control is not necessary in most
applications when plasma arc cutting or gouging.
Preheat temperature control may be necessary on
high carbon alloy steels and heat treated aluminum for
crack resistance and hardness control. Job conditions, prevailing codes, alloy level, and other considerations may also require preheat temperature control.
The recommended minimum preheat temperature for
plate thickness up to 1/2 in. (12.7mm) is 70°F (21.1°C).
Higher temperatures may be used as required by the
job conditions and/or prevailing codes. If cracking or
excessive hardness occurs on the cut face, higher preheat temperature may be required.
PROCEDURE RECOMMENDATIONS
When properly used, plasma arc cutting or gouging is
a very economical process. Improper use will result in
a very high operating cost.
GENERAL - IN ALL CASES
• Follow safety precautions as printed throughout this
manual and on the machine.
THIN GAUGE SHEET METAL
Output set below 45 Amps.
• The nozzle may be dragged on the metal surface,
touching it lightly to the surface after piercing a hole.
Current control should be set below the mid-range.
• Do not allow cable or body to contact hot surface.
OPERATION
B-7 B-7
PRO-CUT 80
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WARNING
Torch Standoff
DRAG thru 1/16"
Standoff
Machine Output Setting
45
Output Setting
Min. thru Mid. Range
Page 22
THICK SECTIONS OF METAL
Output set above 45 Amps.
• The best quality and consumable life will be
obtained by holding the torch off the surface about
3/16 in. (4.7mm). Too long an arc may compromise
cut quality and consumable life. The nozzle should
NOT be dragged on the work.
• Use of the S22151 Drag Cup will maintain the proper standoff. The only time not to use the drag cup
when the output control is set above mid-range is in
special, tight corners. Always hold at least a 1/8 in.
(3.2mm) standoff in those situations.
• If piercing is required, slowly lower the torch at an
angle of about 30° to blow the dross away from the
torch tip and slowly rotate the torch to a vertical
position as the arc becomes deeper. This process
will blow a lot of molten metal and dross. Be careful! Blow the dross away from the torch, the operator and any flammable objects.
• Where possible, start the cut from the edge of the
workpiece.
• Keep moving! A steady speed is necessary. Do not
pause.
• Do not allow the torch cable or body to contact a
hot surface.
SUGGESTIONS FOR EXTRA UTILITY
FROM THE PRO-CUT SYSTEM
ELECTRIC SHOCK can kill.
• Turn off machine at the disconnect
switch on the front of the machine
before tightening, cleaning or replacing consumables.
1. Occasionally an oxide layer may form over the tip
of the electrode, creating an insulating barrier
between the electrode and nozzle. This will result in
the tripping of the Pro-Cut's safety circuit. When
this happens, turn the power off, remove the nozzle and electrode and use the electrode to rub
against the inside bottom surface of the nozzle.
This will help remove any oxide buildup. Replace
the nozzle, turn on the power and continue cutting.
If the Parts-in-Place circuit (safety status indicator
light) continues to trip after cleaning the consumables, replace them with a new set. Do not continue to cut with excessively worn consumables as
this can cause damage to the torch head and will
degrade cut quality.
2. To improve consumable life, here are some suggestions that may be useful:
a. Never drag the nozzle on the work surface if
the output control knob is above 45 Amps.
b. Make sure the air supply to the Pro-Cut is
clean and free of oil. Use several extra in-line
filters if necessary.
c. Use the lowest output setting possible to
make a good quality cut at the desired cut
speed.
d. Minimize dross buildup on the nozzle tip by
starting the cut from the edge of the plate
when possible.
e. Pierce cutting should be done only when nec-
essary. If piercing, angle the torch about 30°
from the plane perpendicular to the workpiece, transfer the arc, then bring the torch
perpendicular to the work and begin parallel
movement.
f. Reduce the number of pilot arc starts without
transferring to the work.
g. Reduce the pilot arc time before transferring to
the work.
h. Set air pressure to recommended setting. A
higher or lower pressure will cause turbulence
in the plasma arc, eroding the orifice of the
nozzle tip.
i. Use only Lincoln consumable parts. These
parts are patented. Using any other replacement consumables may cause damage to the
torch or reduce cut quality.
OPERATION
B-8 B-8
PRO-CUT 80
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WARNING
Torch Standoff
1/8" thru 3/16"
Standoff
Machine Output Setting
45
Output Setting
Mid. thru Max. Range
Page 23
MACHINE INTERFACE
The PRO-CUT 80 comes standard with a machine
interface. Interface signals provided include: arc start,
arc initiated, and arc voltage.These signals are accessible through the 14 pin MS connector on the case
front.
ARC START:
The Arc Start circuit allows for triggering of the power
source to commence cutting. This circuit can be
accessed through pins K and M of the 14 pin MS connector.The circuit has a 17 VDC nominal open circuit
voltage and requires a dry contact closure to activate.
ARC INITIATED:
The Arc Initiated circuit provides information as to
when a cutting arc has transferred to the work piece.
This circuit can be 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 circuit should be limited to 0.3 A for either 120VAC or
30VDC.
ARC VOLTAGE:
The Arc Voltage circuit can be used for activating a
torch height control. This circuit can be accessed
through pins D and G of the 14 pin MS connector. The
circuit provides full electrode to work arc voltage (no
voltage divider, 335VDC maximum).
Users wishing to utilize the Machine Interface can
order a K867 Universal Adapter (please adhere to the
pin locations stated above) or manuf acture a 14 pin MS
connector cable assembly.
OPERATION
B-9
B-9
PRO-CUT 80
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14-PIN BOX RECEPTACLE, FRONT VIEW
J=347
I=348
H
N
G=343
F
E
D=344
C
L
Arc Start
Arc Voltage
Arc Initiated
M=4A
K=2A
Page 24
NOTES
B-10 B-10
PRO-CUT 80
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Page 25
TABLE OF CONTENTS
- ACCESSORIES -
Accessories...........................................................................................................................Section C
Options/Accessories...................................................................................................................C-2
Section C-1 Section C-1
PRO-CUT 80
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Page 26
GENERAL OPTIONS /
ACCESSORIES
The following options/accessories are available for
your PRO-CUT 80 from your local Lincoln Distributor.
K1681-1 Undercarriage - A valet style undercarriage
with pull-out handle for machine only. Provides torch
and work cable storage.
S22147-043 - Vortech™ nozzle with an .043” (1.2 mm)
Orifice (For 35 - 60 Amps)
S22147-053 - Vortech™ nozzle with an .053” (1.3 mm)
Orifice (For 60 - 85 Amps)
S22147-082 - VortechTMnozzle with an .082” (2.1 mm)
Orifice (For Gouging at 60 -85 Amps)
S22149 - Electrode - replacement electrodes for cutting.
S22150 - Shield Cup - This shields 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 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 mechanized versions.
ALWAYS USE GENUINE LINCOLN ELECTRIC
ELECTRODES AND VORTECH™ NOZZLES
• Only Genuine Lincoln Electric consumables yield
the best cutting performance for the PRO-CUT 80.
• The patent pending VORTECH™ nozzle provides
an extra “kick” of swirl as the arc exits the nozzle,
which improves cutting performance. No other nozzle has this capability or can match its performance.
ACCESSORIES
C-2 C-2
PRO-CUT 80
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Page 27
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Section D-1 Section 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 Component Locations .....................................................................................................D-4
Page 28
ELECTRIC SHOCK can kill.
• Have an electrician install and service
this equipment.
• Turn the input power off at the fuse box
before working on equipment.
• Do not touch electrically hot parts.
• Prior to performing preventative maintenance, perform the following capacitor discharge procedure to
avoid electric shock.
INPUT FILTER CAPACITOR
DISCHARGE PROCEDURE
1. Turn off input power or disconnect input power
lines.
2. Remove the 5/16 in. hex head screws from the side
and top of the machine and remove wrap-around
machine cover.
3. Be careful not to make contact with the capacitor
terminals that are located on the top and bottom of
the Power Board on the right side of the machine.
4. Obtain a high resistance and high wattage resistor
(25-1000 ohms and 25 watts minimum). This resistor 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 Figure D.1.
6. Use electrically insulated gloves and insulated pliers. Hold the body of the resistor and connect
resistor leads across the two capacitor terminals.
Hold the resistor in place for 10 seconds. DO NOT
TOUCH CAPACITOR TERMINALS WITH YOUR
BARE HANDS.
7. Repeat the discharge procedure for the other
capacitor.
8. Check voltage across the terminals of all capacitors with a DC voltmeter. Polarity of capacitor terminals is marked on the Power Board above terminals. Voltage should be zero. If any voltage
remains, repeat this capacitor discharge procedure.
MAINTENANCE
D-2 D-2
PRO-CUT 80
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WARNING
CAPACITOR
TERMINALS
POWER
RESISTOR
POWER
BOARD
RIGHT SIDE OF MACHINE
INSULATED
GLOVES
INSULATED
PLIERS
FIGURE D.1 — LOCATION OF INPUT FILTER CAPACITOR TERMINALS
Page 29
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MAINTENANCE
D-3 D-3
PRO-CUT 80
ROUTINE MAINTENANCE
1. Keep the cutting or gouging area and the area
around the machine clean and free of combustible
materials. No debris should be allowed to collect
which could obstruct air flow to the machine.
2. Every 6 months or so, the machine should be
cleaned with a low pressure airstream. Keeping the
machine clean will result in cooler operation and
higher reliability. Be sure to clean these areas. SEE
FIGURE D.2
- Power, Output and Control printed circuit boards
and heat sinks
- Power Switch
- Main Transformer
- Input Rectifier
3. Examine the sheet metal case for dents or breakage. Repair the case as required. Keep the case in
good condition to insure that high voltage parts are
protected and correct spacings are maintained. All
external sheet metal screws must be in place to
insure case strength and electrical ground continuity.
4. Check the air regulator filter to be sure it does not
become clogged. The air filter on the machine is
self draining and will not have to be emptied.
5. Check the filter element every several months to
see if it is clogged (weekly in very dirty environments). Replace if necessary by first removing the
two screws that attach the filter cage to the back
panel assembly, then slide the cage away from the
back of the machine and remove. Next, twist the
clear filter bowl until it comes off (be careful not to
lose the o-ring seated at the top of the bowl
threads). Unscrew the filter element and replace
with new element. Assemble parts in reverse order
as described above.
6. Inspect the cable periodically for any slits or puncture marks in the cable jacket. Replace if necessary. Check to make sure that nothing is crushing
the cable and blocking the flow of air through the
air tube inside. Also, check for kinks in the cable
periodically and relieve any so as not to restrict the
flow of air to the torch.
PERIODIC MAINTENANCE
ELECTRIC SHOCK can kill.
• Turn off machine at the disconnect
switch on the front of the machine
before tightening, cleaning or replacing
consumables.
Change consumables as required.
1. Thermal Protection
Two thermostats protect the machine from excessive
operating temperatures. Excessive temperatures may
be caused by a lack of cooling air or by operating the
machine beyond the duty cycle and output rating. If
excessive operating temperatures should occur, the
yellow thermal LED will light and the thermostat will
prevent output voltage or current.
Thermostats are self-resetting once the machine cools
sufficiently. If the thermostat shutdown was caused by
excessive output or duty cycle and the fan is operating normally, the Power Switch may be left on and the
reset should occur within a 15 minute period. If the fan
is not turning or the air intake louvers were obstructed,
then the power must be switched off and the fan problem or air obstruction must be corrected.
2. Filter Capacitor Conditioning (PRO-CUT 80, 400460 VAC only)
A protection circuit is included to monitor the voltage
across filter capacitors C1 and C2. In the event that
the capacitor voltage is too high, the protection circuit
will prevent output. The protection circuit may prevent
output providing all these circumstances are met:
a. Machine is connected for 400-460 or
460-575 VAC input.
b. Machine did not have power applied for many
months.
c. Machine will not produce output when power is
first switched on.
If these circumstances apply, the proper action is to
switch the machine on and let it idle for up to 30 minutes. This is required to condition the filter capacitors
after an extended storage time. The protection circuit
will automatically reset once the capacitor conditioning and resultant voltage levels are acceptable. It may
be necessary to turn the power switch off and back on
again after this period.
WARNING
Page 30
6
4
3
5
1
2
Maintenance
D-4 D-4
PRO-CUT 80
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FIGURE D.2 – MAJOR COMPONENT LOCATIONS
1. Case Front
2. Base and Case Back
3. Center Panel Assembly
4. Output Board Heatsink
5. Power Board Assembly
6. Case Wraparound
Page 31
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Section E-1 Section E-1
PRO-CUT 80
Theory of Operation .............................................................................................................Section E
General Description ....................................................................................................................E-2
Input Line Voltage, Contactor and Main Transformer.................................................................E-2
Precharge and Protection...........................................................................................................E-3
Main Transformer ........................................................................................................................E-4
Output Board and Torch .............................................................................................................E-5
Control and Display Boards........................................................................................................E-6
Protection Circuits ......................................................................................................................E-7
Overload Protection..............................................................................................................E-7
Thermal Protection ...............................................................................................................E-7
Insulated Gate Bipolar Transistor (IGBT) Operation ...................................................................E-8
Pulse Width Modulation (PWM) ..................................................................................................E-9
Minimum Output...................................................................................................................E-9
Maximum Output..................................................................................................................E-9
TABLE OF CONTENTS
-THEORY OF OPERATION SECTION-
INPUT
LINE
SWITCH
INPUT
RECTIFIER
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
TRIGGER & SAFETY
ELECTRODE & TRANSFER
CURRENT FEEDBACK
PILOT ENABLE
ELECTRODE SOLENOID ENABLE
AIR SOLENOID ENABLE
AIR
SOLENOID
TRIGGER & SAFETY
E
L
E
C
T
R
O
D
E
S
O
L
E
N
O
I
D
TORCH
CONNECTOR
ELECTRODE
NOZZLE
WORK
R
E
C
O
N
N
E
C
T
S
W
T
C
H
I
POWER BOARD
CR 1
RELAY
IGBT
IGBT
IGBT
IGBT
CAPACITOR
CAPACITOR
CURRENT
TRANSFORMER
CONTROL BOARD
DISPLAY BOARD
18/36VAC
12VAC
24VAC
MAIN
TRANSFORMER
OUTPUT BOARD
CHOKE
PILOT
TRANSISTOR
THERMOSTATS
115VAC
REMOTE
INTERFACE
RECEPTACLE
&
2
& 2
FIGURE E.1 – PRO-CUT 80 BLOCK LOGIC DIAGRAM
Page 32
GENERAL DESCRIPTION
The PRO-CUT 80 is a constant current, continuous
control plasma cutting power source. The inverter
based power supply design is controlled by a microprocessor control board. The control system has a
safety mechanism to insure that the nozzle and electrode are in place before cutting or gouging. The PROCUT 80 initiates the plasma arc with a simple, yet reliable, touch start mechanism. This system eliminates
many of the problems associated with hi-frequency
type start systems. When powered up, the machine
performes some rudimentary self diognostics.
INPUT LINE VOLTAGE, SWITCH
AND MAIN TRANSFORMER
The single-phase or three-phase input power is connected to the machine, via an input line cord, to a
switch located on the front panel.
A reconnect panel and voltage range switch allow the
user to configure the machine for either a low or high
input voltage and also connect the auxiliary transformer for the appropriate input voltage.
The auxiliary transformer develops the appropriate AC
voltages to operate the cooling fan, the control board
and the plasma output board.
THEORY OF OPERATION
E-2 E-2
PRO-CUT 80
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FIGURE E.2 – INPUT LINE VOLTAGE
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
INPUT
LINE
SWITCH
INPUT
RECTIFIER
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
TRIGGER & SAFETY
ELECTRODE & TRANSFER
CURRENT FEEDBACK
PILOT ENABLE
ELECTRODE SOLENOID ENABLE
AIR SOLENOID ENABLE
AIR
SOLENOID
TRIGGER & SAFETY
E
L
E
C
T
R
O
D
E
S
O
L
E
N
O
I
D
TORCH
CONNECTOR
ELECTRODE
NOZZLE
WORK
R
E
C
O
N
N
E
C
T
S
W
T
C
H
I
POWER BOARD
CR 1
RELAY
IGBT
IGBT
IGBT
IGBT
CAPACITOR
CAPACITOR
CURRENT
TRANSFORMER
CONTROL BOARD
DISPLAY BOARD
18/36VAC
12VAC
24VAC
MAIN
TRANSFORMER
OUTPUT BOARD
CHOKE
PILOT
TRANSISTOR
THERMOSTATS
115VAC
REMOTE
INTERFACE
RECEPTACLE
&
2
& 2
Page 33
PRECHARGE AND PROTECTION
The input voltage is rectified by the input rectifier. The
resultant DC voltage is applied, through the reconnect
switch, to the power board. The power board contains
precharging circuitry for the safe charging of the input
filter capacitors. Once the capacitors are precharged
and balanced the control board activates the CR1+
CR2 input relays. This connects full input power to the
filter capacitors. When the filter capacitors are fully
charged they act as power supplies for the IGBT
switching circuit. The Insulated Gate Bipolar Transistors supply the main transformer primary winding
with DC current flow. See IGBT Operation discussion
and diagrams in this section.
The power board also monitors the filter capacitors for
voltage balance and under or overvoltage. If either
should occur, the appropriate signal is sent to the control 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
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NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
WORK
INPUT
LINE
SWITCH
INPUT
RECTIFIER
"A"
L
E
A
D
AUXILIARY
TRANSFORMER
AIR
PRESSURE
SWITCH
115VAC
R
E
C
O
N
N
E
C
T
S
W
I
T
C
H
P
R
O
T
E
C
T
I
O
N
SIGNAL
18/36VAC
FAN
MOTOR
THERMOSTATS
OUTPUT
CONTROL
POWER BOARD
2
&
CR 1
RELAY
IGBT
CAPACITOR
IGBT
IGBT
CAPACITOR
IGBT
CR 1
& 2
RELAY
DRIVE
SIGNAL
CURRENT
TRANSFORMER
IGBT
GATE
SIGNALS
CONTROL BOARD
A
R
I
E
R
A
L
D
O
Y
W
DISPLAY BOARD
ELECTRODE
MAIN
TRANSFORMER
TRIGGER & SAFETY
ELECTRODE & TRANSFER
CURRENT FEEDBACK
PILOT ENABLE
ELECTRODE SOLENOID ENABLE
S
A
F
E
T
Y
AIR SOLENOID ENABLE
T
H
E
R
M
A
L
OUTPUT BOARD
PILOT
TRANSISTOR
12VAC
24VAC
CHOKE
TRIGGER & SAFETY
NOZZLE
TORCH
CONNECTOR
E
L
E
C
T
R
O
D
E
S
O
L
E
N
O
I
D
SOLENOID
REMOTE
INTERFACE
RECEPTACLE
AIR
Page 34
THEORY OF OPERATION
E-4 E-4
PRO-CUT 80
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FIGURE E.4 – MAIN TRANSFORMER
MAIN TRANSFORMER
Each IGBT pair acts as a switch assembly. Each
assembly feeds a separate, oppositely wound primary
winding of the main transformer. The reverse direction
of current flow through the main transformer primaries
and the offset timing of the IGBT pairs induce an AC
square wave output signal at the secondary of the
main transformer.
The DC current flow through each primary winding is
redirected or "clamped" back to each respective filter
capacitor when the IGBTs are turned off. This is needed due to the inductance of the transformer primary
winding.
The primary currents also pass through the current
transformer, which sends a signal to the control board.
If the primary currents are not equal, the control board
compensates by adjusting the IGBT gate signals.
The firing of both IGBT pairs occurs during halves of
the 50 microsecond intervals, creating a constant
20KHZ output.
The secondary portion of the main transformer is made
up of two separate windings. One secondary winding
supplies the electrode-to-work voltage. This is the
high current winding, which is capable of supplying
maximum output current during the cutting process.
The other secondary winding supplies the electrodeto-nozzle voltage for the pilot arc current. The conductor in this winding is smaller since the pilot current
is considerably less than the cutting current. While
one winding is conducting the other winding is at a limited voltage and aids in the arc transfer to and from the
workpiece.
WORK
INPUT
LINE
SWITCH
INPUT
RECTIFIER
"A"
L
E
A
D
AUXILIARY
TRANSFORMER
AIR
PRESSURE
SWITCH
115VAC
R
E
C
O
N
N
E
C
T
S
W
I
T
C
H
P
R
O
T
E
C
T
I
O
N
SIGNAL
18/36VAC
FAN
MOTOR
THERMOSTATS
OUTPUT
CONTROL
POWER BOARD
2
&
CR 1
RELAY
IGBT
CAPACITOR
IGBT
IGBT
CAPACITOR
IGBT
CR 1
& 2
RELAY
DRIVE
SIGNAL
CURRENT
TRANSFORMER
IGBT
GATE
SIGNALS
CONTROL BOARD
A
R
I
E
R
A
L
D
O
Y
W
DISPLAY BOARD
ELECTRODE
MAIN
TRANSFORMER
TRIGGER & SAFETY
ELECTRODE & TRANSFER
CURRENT FEEDBACK
PILOT ENABLE
ELECTRODE SOLENOID ENABLE
S
A
F
E
T
Y
AIR SOLENOID ENABLE
T
H
E
R
M
A
L
OUTPUT BOARD
PILOT
TRANSISTOR
12VAC
24VAC
CHOKE
TRIGGER & SAFETY
NOZZLE
TORCH
CONNECTOR
E
L
E
C
T
R
O
D
E
S
O
L
E
N
O
I
D
SOLENOID
REMOTE
INTERFACE
RECEPTACLE
AIR
Page 35
OUTPUT BOARD AND TORCH
The output board contains an Insulated Gate Bipolar
Transistor (IGBT) which, upon receiving a pilot signal from
the control board, either enables or disables the current in
the pilot winding. The cutting and pilot rectifier diodes are
also incorporated in the output board. There are two
diodes for the pilot winding and four diodes for the cutting
winding.
There are two P.C. board mounted current sensors. One
sensor regulates pilot and cutting current. The other sensor indicates to the control board when and how much
current transfers to the workpiece.
The output board also includes the trigger circuitry, the gas
solenoid driver, the electrode solenoid driver and the torch
parts-in-place circuitry and remote interface circutry.
The output choke, which is in series with both the pilot circuit and the cutting circuit, provides current filtering to
enhance arc stability.
The PCT 80 torch uses a patented touch start mechanism
that provides superior starting performance over other
touch start systems. The torch head consists of 3 major
parts: torch body, insulator and piston. The insulator provides an electrical barrier between the piston and torch
body. The piston provides a path for electrical current to
the electrode. The piston also drives the electrode to the
nozzle for arc initiation. The torch body contains the main
torch components: the trigger, pilot arc, cutting arc, and air
flow systems are included.
A copper nozzle with a patented internal swirl is used to
focus the arc. A small, precise hole in the end of the nozzle constricts the arc and increases the current density.
As the air enters the torch head, it is directed between
the electrode and nozzle for maximum electrode cooling.
A portion of the cooling air exits the chamber through
vents in the side of the nozzle. A swirl texture located
inside the bottom of the nozzle increases the plenum air
swirl strength, and improves arc start reliability and partsin-place verification.
Plasma arc initiation occurs as follows: First, in the idle
state, a spring inside the torch head pushes the piston
and electrode forward to make continuity with the nozzle.
When the trigger is pulled, air flow begins and creates
enough back force on the electrode to overcome the
force of the spring. However, the solenoid valve allows
enough forward force on the piston to maintain continuity between the consumables. After this continuity has
been verified by the Pro-Cut’s parts-in-place circuit, output current is established and regulated. Once the current stabilizes, the solenoid valve turns off, removing the
forward force on the piston. The back pressure drives
the piston and electrode away from the nozzle, creating
the plasma arc. The air stream forces the arc out the orifice of the nozzle. This appears as a pilot arc, which can
then be transferred for cutting.
THEORY OF OPERATION
E-5 E-5
PRO-CUT 80
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FIGURE E.5 – PLASMA OUTPUT BOARD AND TORCH
INPUT
LINE
SWITCH
INPUT
RECTIFIER
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
TRIGGER & SAFETY
ELECTRODE & TRANSFER
CURRENT FEEDBACK
PILOT ENABLE
ELECTRODE SOLENOID ENABLE
AIR SOLENOID ENABLE
AIR
SOLENOID
TRIGGER & SAFETY
E
L
E
C
T
R
O
D
E
S
O
L
E
N
O
I
D
TORCH
CONNECTOR
ELECTRODE
NOZZLE
WORK
R
E
C
O
N
N
E
C
T
S
W
T
C
H
I
POWER BOARD
CR 1
RELAY
IGBT
IGBT
IGBT
IGBT
CAPACITOR
CAPACITOR
CURRENT
TRANSFORMER
CONTROL BOARD
DISPLAY BOARD
18/36VAC
12VAC
24VAC
MAIN
TRANSFORMER
OUTPUT BOARD
CHOKE
PILOT
TRANSISTOR
THERMOSTATS
115VAC
REMOTE
INTERFACE
RECEPTACLE
&
2
& 2
Page 36
CONTROL AND DISPLAY BOARDS
The control board receives status and analog feedback signals from the output board, display board,
power board and various sensors. The processor
interprets these signals, makes decisions and changes
machine mode and output to satisfy the requirements
as defined by the internal software. The control board
regulates the output of the machine by controlling the
IGBT switching times through pulse width modulation
circuitry. See Pulse Width Modulation in this section.
The display board receives commands from the control board and, via indicator lights, communicates
PRO-CUT 80 status and operating conditions to the
user.
THEORY OF OPERATION
E-6 E-6
PRO-CUT 80
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FIGURE E.6 – CONTROL AND DISPLAY BOARDS
INPUT
LINE
SWITCH
INPUT
RECTIFIER
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
TRIGGER & SAFETY
ELECTRODE & TRANSFER
CURRENT FEEDBACK
PILOT ENABLE
ELECTRODE SOLENOID ENABLE
AIR SOLENOID ENABLE
AIR
SOLENOID
TRIGGER & SAFETY
E
L
E
C
T
R
O
D
E
S
O
L
E
N
O
I
D
TORCH
CONNECTOR
ELECTRODE
NOZZLE
WORK
R
E
C
O
N
N
E
C
T
S
W
T
C
H
I
POWER BOARD
CR 1
RELAY
IGBT
IGBT
IGBT
IGBT
CAPACITOR
CAPACITOR
CURRENT
TRANSFORMER
CONTROL BOARD
DISPLAY BOARD
18/36VAC
12VAC
24VAC
MAIN
TRANSFORMER
OUTPUT BOARD
CHOKE
PILOT
TRANSISTOR
THERMOSTATS
115VAC
REMOTE
INTERFACE
RECEPTACLE
&
2
& 2
Page 37
PROTECTION CIRCUITS
Protection circuits are designed into the PRO-CUT 80
machine to sense trouble and shut down the machine
before the trouble damages internal machine components. Both overload and thermal protection circuits
are included.
OVERLOAD PROTECTION
The PRO-CUT 80 is electrically protected from producing higher than normal output currents. If the output current exceeds 85-90 amps, an electronic protection circuit limits the current to within the capabilities of the machine.
Another protection circuit monitors the voltage across
the input filter capacitors. If the filter capacitor voltage
is too high, too low or not balanced the protection circuit may prevent machine output.
THERMAL PROTECTION
Two thermostats protect the machine from excessive
operating temperatures. One thermostat is located on
the output choke and the other on the power board
IGBT heat sink. Excessive temperatures may be
caused by a lack of cooling air or by operating the
machine beyond the duty cycle and output rating. If
excessive operating temperatures should occur, the
thermal status indicator will light and the thermostat
will prevent output voltage or current.
Thermostats are self-resetting once the machine cools
sufficiently. If the thermostat shutdown was caused
by excessive output or duty cycle and the fan is operating normally, the power switch may be left on and
the reset should occur within a 15 minute period. If
the fan is not turning or the air intake louvers are
obstructed, the input power must be removed and the
fan problem or air obstruction must be corrected.
THEORY OF OPERATION
E-7 E-7
PRO-CUT 80
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Page 38
INSULATED GATE BIPOLAR
TRANSISTOR (IGBT) OPERATION
An IGBT is a type of transistor. IGBTs are semiconductors well suited for high frequency switching and
high current applications.
Drawing A shows an IGBT in a passive mode. There
is no gate signal, zero volts relative to the source, and
therefore, no current flow. The drain terminal of the
IGBT may be connected to a voltage supply; but since
there is no conduction the circuit will not supply current to components connected to the source. The circuit is turned off like a light switch in the OFF position.
Drawing B shows the IGBT in an active mode. When
the gate signal, a positive DC voltage relative to the
source, is applied to the gate terminal of the IGBT, it
is capable of conducting current. A voltage supply
connected to the drain terminal will allow the IGBT to
conduct and supply current to circuit components
coupled to the source. Current will flow through the
conducting IGBT to downstream components as long
as the positive gate signal is present. This is similar
to turning ON a light switch.
THEORY OF OPERATION
E-8 E-8
PRO-CUT 80
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FIGURE E.7 – CONTROL AND DISPLAY BOARDS
DRAIN
SOURCE
GATE
INJECTING LAYER
BUFFER LAYER
DRAIN DRIFT REGION
BODY REGION
p +
n +
n -
p
n + n +
DRAIN
SOURCE
GATE
INJECTING LAYER
BUFFER LAYER
DRAIN DRIFT REGION
BODY REGION
p +
n +
n -
p
n + n +
POSITIVE
VOLTAGE
APPLIED
B. ACTIVE
A. PASSIVE
Page 39
PULSE WIDTH MODULATION
The term PULSE WIDTH MODULATION describes
how much time is devoted to conduction in the positive and negative portions of the cycle. Changing the
pulse width is known as MODULATION. Pulse Width
Modulation (PWM) is the varying of the pulse width
over the allowed range of a cycle to affect the output
of the machine.
MINIMUM OUTPUT
By controlling the duration of the gate signal, the IGBT
is turned on and off for different durations during a
cycle. The top drawing below shows the minimum
output signal possible over a 50-microsecond time
period.
The positive portion of the signal represents one IGBT
group1conducting 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 is devoted to conducting, the output
power is minimized.
MAXIMUM OUTPUT
By holding the gate signals on for 22 microseconds
each and allowing only 3 microseconds of dwell time
(off time) during the 50-microsecond cycle, the output
is maximized. The darkened area under the top curve
can be compared to the area under the bottom curve.
The more dark area under the curve, the more power
is present.
THEORY OF OPERATION
E-9 E-9
PRO-CUT 80
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1
An IGBT group consists of two IGBT modules feeding one transformer primary winding.
MINIMUM OUTPUT
MAXIMUM OUTPUT
22
50
22
3
48
50
sec
sec
sec
sec
sec
sec
sec
sec
FIGURE E.8 – TYPICAL IGBT OUTPUTS
Page 40
NOTES
E-10 E-10
PRO-CUT 80
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Page 41
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Section F-1 Section F-1
PRO-CUT 80
Troubleshooting & Repair Section .................................................................................Section F
How to Use Troubleshooting Guide ......................................................................................F-2
PC Board Troubleshooting Procedures and Replacement ...................................................F-3
Troubleshooting Guide...........................................................................................................F-4
Test Procedures
Input Filter Capacitor Discharge Procedure..................................................................F-10
Input Rectifier Test ........................................................................................................F-12
Primary Power Board Resistance Test and Capacitor Voltage Test .............................F-15
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
Replacement Procedures
Control Board Removal and Replacement ...................................................................F-40
Display Board Removal and Replacement ...................................................................F-43
Output Power Board Removal and Replacement.........................................................F-46
Primary Power Board and Filter Capacitor Removal and Replacement ......................F-50
Input Rectifier Bridge Removal and Replacement........................................................F-54
Retest after Repair ........................................................................................................F-57
TABLE OF CONTENTS
TROUBLESHOOTING & REPAIR SECTION
Page 42
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HOW TO USE TROUBLESHOOTING GUIDE
Service and repair should be performed by only Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and machine
operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please
observe all safety notes and precautions detailed throughout this manual.
TROUBLESHOOTING & REPAIR
F-2 F-2
PRO-CUT 80
CAUTION
This Troubleshooting Guide is provided to help
you locate and repair possible machine malfunctions. Simply follow the three-step procedure
listed below.
Step 1. LOCATE PROBLEM (SYMPTOM). Look
under the column labeled “PROBLEM (SYMPTOMS). This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the symptom that the
machine is exhibiting. Symptoms are grouped
into four main categories: Output Problems,
Function Problems, Cutting Problems and LED
Function Problems.
Step 2. PERFORM EXTERNAL TESTS. The
second column, labeled “POSSIBLE AREAS OF
MISADJUSTMENT(S)”, lists the obvious external
possibilities that may contribute to the machine
symptom. Perform these tests/checks in the
order listed. In general, these tests can be conducted without removing the case wrap-around
cover.
Step 3. PERFORM COMPONENT TESTS. The
last column, labeled “Recommended Course of
Action” lists the most likely components that may
have failed in your machine. It also specifies the
appropriate test procedure to verify that the subject component is either good or bad. If there are
a number of possible components, check the
components in the order listed to eliminate one
possibility at a time until you locate the cause of
your problem.
All of the referenced test procedures referred to in
the Troubleshooting Guide are described in detail
at the end of this chapter. Refer to the
Troubleshooting and Repair Table of Contents to
locate each specific Test Procedure. All of the
referred to test points, components, terminal
strips, etc., can be found on the referenced electrical wiring diagrams and schematics. Refer to
the Electrical Diagrams Section Table of Contents
to locate the appropriate diagram.
WARNING
If for any reason you do not understand the test procedures or are unable to perform the test/repairs
safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before
you proceed. Call 1-800-833-9353.
Page 43
ELECTRIC SHOCK can kill.
Have an electrician install and service
this equipment. Turn the machine OFF
before working on equipment. Do not
touch electrically hot parts.
Sometimes machine failures appear to be due to PC
board failures. These problems can sometimes be
traced to poor electrical connections. To avoid problems when troubleshooting and replacing PC boards,
please use the following procedure:
1. Determine to the best of your technical ability that
the PC board is the most likely component causing the failure symptom.
2. Check for loose connections at the PC board to
assure that the PC board is properly connected.
3. If the problem persists, replace the suspect PC
board using standard practices to avoid static
electrical damage and electrical shock. Read the
warning inside the static resistant bag and perform
the following procedures:
PC Board can be damaged by
static electricity.
• Remove your body’s static charge
before opening the static-shielding bag. Wear an anti-static wrist
strap. For safety, use a 1 Meg
ohm resistive cord connected to a
grounded part of the equipment
frame.
• If you don’t have a wrist strap,
touch an unpainted, grounded,
part of the equipment frame.
Keep touching the frame to prevent static build-up. Be sure not
to touch any electrically live parts
at the same time.
• Tools which come in contact with the PC Board must
be either conductive, anti-static or static-dissipative.
• Remove the PC Board from the static-shielding bag
and place it directly into the equipment. Don’t set
the PC Board on or near paper, plastic or cloth which
could have a static charge. If the PC Board can’t be
installed immediately, put it back in the staticshielding bag.
• If the PC Board uses protective shorting jumpers,
don’t remove them until installation is complete.
• If you return a PC Board to The Lincoln Electric
Company for credit, it must be in the static-shielding
bag. This will prevent further damage and allow
proper failure analysis.
4. Test the machine to determine if the failure symp-
tom has been corrected by the replacement PC
board.
NOTE: Allow the machine to heat up so that all elec-
trical components can reach their operating
temperature.
5. Remove the replacement PC board and substitute
it with the original PC board to recreate the original
problem.
a. If the original problem does not reappear
by substituting the original board, then the
PC board was not the problem. Continue
to look for bad connections in the control
wiring harness, junction blocks, and terminal strips.
b. If the original problem is recreated by the
substitution of the original board, then the
PC board was the problem. Reinstall the
replacement PC board and test the
machine.
6. Always indicate that this procedure was followed
when warranty reports are to be submitted.
NOTE: Following this procedure and writing on the
warranty report, “INSTALLED AND SWITCHED
PC BOARDS TO VERIFY PROBLEM,” will help
avoid denial of legitimate PC board warranty
claims.
TROUBLESHOOTING & REPAIR
F-3 F-3
PRO-CUT 80
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PC BOARD TROUBLESHOOTING PROCEDURES
WARNING
ATTENTION
Static-Sensitive
Devices
Handle only at
Static-Safe
Workstations
Reusable
Container
Do Not Destroy
Page 44
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TROUBLESHOOTING & REPAIR
F-4 F-4
PRO-CUT 80
Observe Safety Guidelines TROUBLESHOOTING GUIDE
detailed in the beginning of this manual.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-800-833-9353.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
Major physical or electrical damage is evident when the sheet
metal cover(s) are removed.
1. Contact your local authorized
Lincoln Electric Field Service
Facility for technical assistance.
1. Contact the Lincoln Electric
Service Department,
1-800-833-9353 (WELD).
Machine is dead – no output – no 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 panel.
3. Check for blown or missing
fuses in the input lines and the
0.6 amp slow blow reconnect
fuse.
1. Check the input power switch
(S1) for proper operation. See
the Wiring Diagram.
2. Check the leads associated
with the power switch (S1) and
the auxiliary transformer (T2) for
loose or faulty connections.
See the Wiring Diagram.
3. Perform the Auxiliary Trans-
former Test.
Machine is dead - not output - no status indicator lights - fans run.
1. Check the input voltage at the
machine. Input voltage must
match the rating plate and the
reconnect panel.
1. Perform the Auxiliary
Transformer Test.
2. Perform the Low Voltage
Circuit Test.
3. Perform the Input Rectifier
Test.
4. The control board may be
faulty. Replace.
5. The display board may be
faulty. Replace.
All status indicators remain lit immediately after power up.
1. The microprocessor has experienced a memory fault. Contact
your Local Lincoln Authorized
Field Service Facility.
1. The control board may be
faulty. Replace.
Page 45
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TROUBLESHOOTING & REPAIR
F-5 F-5
PRO-CUT 80
TROUBLESHOOTING GUIDE Observe Safety Guidelines
detailed in the beginning of this manual.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed.
Call 1-800-833-9353.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS
All the status lights begin to blink within 5 seconds of power up.
1. Make sure the PRO-CUT 80 is
reconnected correctly for the
input voltage being applied. Be
sure to remove input power
and wait at least one minute
before changing the position
of the input voltage range
switch.
1. Perform the Primary Power
Board Resistance Test and
Capacitor 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 the gun trigger is pulled. Only the power LED is lit.
1. Make sure the torch is connected properly to the PRO-CUT 80
machine.
2. Make sure the air supply is connected and operating properly.
3. Make sure the torch head consumable parts are in place and
in good condition. Replace if
necessary.
1. Perform the Auxiliary Trans-
former Test.
2. Perform the Trigger Circuit
Test.
3. Perform the Gas Solenoid
Test.
4. Perform the Torch Continuity
and Solenoid Test.
5. The control board may be
faulty. Replace.
6. The output power board may
be faulty. Perform the Output
Board Resistance Test.
When the torch trigger is pulled, air begins to flow; but no pilot arc is established.
1. Make sure the torch consumables are in place and in good
condition. Replace if necessary.
2. Make sure the air pressure is
set at 70 psi (448 kPa.)
3. Make sure there are no kinks or
restrictions for air flow in the
torch cable.
1. Perform the Torch Continuity
and Solenoid Test.
2. Perform the Low Voltage
Circuit Test.
3. The output board may be faulty.
Perform the Output Board
Resistance Test.
4. The control board may be
faulty. Replace.
Page 46
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TROUBLESHOOTING & REPAIR
F-6 F-6
PRO-CUT 80
Observe Safety Guidelines TROUBLESHOOTING GUIDE
detailed in the beginning of this manual.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-800-833-9353.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS
The air begins to flow when the
torch trigger is pulled. There is a
very brief pilot arc. (Normal is 3
seconds.) The sequence is repeated with subsequent trigger pulls.
1. Make sure the air pressure is
set at 70 psi (448 kPa.)
2. Make sure the torch consumables are in place and in good
condition.
3. Make sure the air flow is not
restricted.
1. Perform the Torch Continuity
and Solenoid Test.
2. The output board may be faulty.
Replace.
3. The control board may be
faulty. Replace.
The cutting arc starts but sputters badly.
1. Make sure the operating procedure is correct for the process.
See the Operation section of
this manual.
2. Make sure the work clamp is
connected tightly to the workpiece.
3. Make sure the torch consumables are in place and in good
condition.
4. Make sure the air supply is not
contaminated with oil or excessive water.
5. Make sure the air pressure is
set at 70 psi (448 kPa.)
1. Perform the Torch Continuity
and Solenoid Test.
2. The output board may be faulty.
Replace.
3. The control board may be
faulty. Replace.
Page 47
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TROUBLESHOOTING & REPAIR
F-7 F-7
PRO-CUT 80
TROUBLESHOOTING GUIDE Observe Safety Guidelines
detailed in the beginning of this manual.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed.
Call 1-800-833-9353.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
CUTTING PROBLEMS
The pilot arc is normal, but the arc will not transfer to the workpiece.
1. Make sure the operating procedure is correct for the process.
See the Operation section of
this manual.
2. Make sure the work clamp is
connected tightly to the workpiece.
3. The workpiece must be electrically conductive material.
1. Check the lead connections X2,
X4 and B21 at the output board.
2. Check the output control
potentiometer (R1). Normal
resistance is 10 ohms. Also
check the associated leads for
loose or faulty connections to
the display board. See the
Wiring Diagram.
3. Check leads #216, #218 and
#219 between the display
board and the control board.
Check for loose or faulty connections. See the Wiring
Diagram.
4. The control board may be
faulty. Replace.
5. The output board may be faulty.
Perform the Output Board
Resistance Test.
6. The display board may be
faulty. Replace.
Page 48
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TROUBLESHOOTING & REPAIR
F-8 F-8
PRO-CUT 80
Observe Safety Guidelines TROUBLESHOOTING GUIDE
detailed in the beginning of this manual.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed.
Call 1-800-833-9353.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
LED FUNCTION PROBLEMS
The Air Low LED is lit. 1. Make sure there is at least 70
psi (448 kPa) of air pressure
connected to the gas connection at the back of the PROCUT 80.
2. Press the purge button and set
the regulator to 70 psi (448
kPa). Do not reset the air pressure while the air is off (not flowing).
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
PCT 80 torch connected properly to the PRO-CUT 80.
2. Make sure the torch consumables are in place and in good
condition.
1. Perform the Torch Continuity
and Solenoid Test.
2. Check leads “N”, “E”, #364, and
#369 between the torch receptacle, the output board, and the
Transformer. (See the Wiring
Diagram)
3. The output board may be faulty.
Replace.
The Safety LED is lit and steady. 1. Press the reset button. If the
torch and consumables are
properly installed, the Safety
LED should turn off.
1. The reset button or associated
wiring may be faulty. See the
Wiring Diagram.
2. Perform the Torch Continuity
and Solenoid Test.
3. The control board may be faulty.
Replace.
4. If the machine operates normally with the Safety LED on, the
display board may be faulty.
Replace.
Page 49
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TROUBLESHOOTING & REPAIR
F-9 F-9
PRO-CUT 80
Observe Safety Guidelines TROUBLESHOOTING GUIDE
detailed in the beginning of this manual.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed.
Call 1-800-833-9353.
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
turn the PRO-CUT 80 off. Allow
the machine to cool. The thermostat(s) will reset themselves.
Either the duty cycle has been
exceeded, the fan is not functioning or the louvers are
blocked.
1. A thermostat may be faulty.
Replace.
2. The control board may be
faulty. Replace.
3. If the machine operates normally with the Thermal LED lit, the
display board may be faulty.
Replace.
Page 50
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TROUBLESHOOTING & REPAIR
F-10 F-10
PRO-CUT 80
INPUT FILTER CAPACITOR DISCHARGE PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and
to avoid electrical shock, please observe all safety notes and precautions detailed
throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
This procedure will drain off any charge stored in the two large capacitors that are part
of the power board assembly. This procedure MUST be performed, as a safety precaution, before conducting any test or repair procedure that requires you to touch internal
components of the machine.
MATERIALS NEEDED
Volt/Ohmmeter (Multimeter)
5/16” Nut driver
Insulated gloves
Insulated pliers
High wattage resistor - 25 to 1000 ohms, 25 watts minimum
This procedure takes approximately 10 minutes to perform.
Page 51
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TROUBLESHOOTING & REPAIR
F-11 F-11
PRO-CUT 80
ELECTRIC SHOCK can kill.
• Have an electrician install and
service this equipment.
• Turn the input power off at the
fuse box before working on
equipment.
• Do not touch electrically hot parts.
• Prior to performing preventative maintenance, perform the following capacitor discharge procedure to avoid electric shock.
DISCHARGE PROCEDURE
1. Turn off input power and disconnect input
power lines.
2. Remove the 5/16" hex head screws from
the wraparound machine cover.
3. Be careful not to make contact with the
capacitor terminals located at the bottom of
the Input Power Board.
4. Obtain a high resistance and high wattage
resistor (25-1000 ohms and 25 watts minimum). This 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.
At the bottom of the PowerBoard
(203,206)(207,202)
6. Use electrically insulated gloves and insulated pliers. Hold the body of the resistor
and connect the resistor leads across the
two capacitor terminals. Hold the resistor in
place for 10 seconds. DO NOT TOUCH
CAPACITOR TERMINALS WITH YOUR
BARE HANDS.
7. Repeat the discharge procedure for the
capacitor on the other two terminals.
8. Check the voltage across the terminals of
all capacitors with a DC voltmeter. Polarity
of the capacitor terminals is marked on the
PC board above the terminals. Voltage
should be zero. If any voltage remains,
repeat this capacitor discharge procedure.
WARNING
CAPACITOR
TERMINALS
POWER
RESISTOR
POWER
BOARD
RIGHT SIDE OF MACHINE
INSULATED
GLOVES
INSULATED
PLIERS
FIGURE F.1 – LOCATION OF INPUT FILTER CAPACITOR TERMINALS
INPUT FILTER CAPACITOR DISCHARGE PROCEDURE (continued)
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TROUBLESHOOTING & REPAIR
F-12 F-12
PRO-CUT 80
INPUT RECTIFIER TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and
to avoid electrical shock, please observe all safety notes and precautions detailed
throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
This test will help determine if the input rectifier has “shorted” or “open” diodes.
MATERIALS NEEDED
Analog voltmeter/ohmmeter (multimeter)
Phillips head screw driver
Wiring diagram
This procedure takes approximately 15 minutes to perform.
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TROUBLESHOOTING & REPAIR
F-13 F-13
PRO-CUT 80
INPUT RECTIFIER TEST (continued)
TEST 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 locations. See Figure F.2. Carefully remove the
silicone sealant from leads #207, #207A,
and #209.
4. With the phillips head screw driver, remove
leads #207, 207A and #209 from the rectifier.
5. Use the analog ohmmeter to perform the
tests detailed in Table F.1. See the Wiring
Diagram.
FIGURE F.2 – INPUT RECTIFIER AND LEADS
#207A
#207
#209A
B
C
TOP VIEW
Page 54
TEST POINT TERMINALS ANALOG METER X10 RANGE
+Probe - Probe Acceptable Meter Readings
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TROUBLESHOOTING & REPAIR
F-14 F-14
PRO-CUT 80
6. If the input rectifier does not meet the acceptable readings outlined in Table F.1, the component may be faulty. Replace.
NOTE: Before replacing the input rectifier (D1)
check the input power switch (S1) and
perform the Primary Power Board
Resistance Test. Also check for leaky
or faulty filter capacitors.
7. If the input rectifier is good, be sure to reconnect leads #207, #207A and #209 to the correct terminals and torque to 31 in.-lbs. Apply
a coating of Essex D-4-8 insulating compound 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
Figure F.2.
INPUT RECTIFIER TEST (continued)
TABLE F.1 INPUT RECTIFIER TEST POINTS
A
B
C
A
B
C
A
B
C
207
207
207
207A
207A
207A
209
209
209
207
207
207
207A
207A
207A
209
209
209
A
B
C
A
B
C
A
B
C
Greater than 1000 ohms
Greater than 1000 ohms
Greater than 1000 ohms
Greater than 1000 ohms
Greater than 1000 ohms
Greater than 1000 ohms
Less than 100 ohms
Less than 100 ohms
Less than 100 ohms
Less than 100 ohms
Less than 100 ohms
Less than 100 ohms
Less than 100 ohms
Less than 100 ohms
Less than 100 ohms
Greater than 1000 ohms
Greater than 1000 ohms
Greater than 1000 ohms
Page 55
PRIMARY POWER BOARD RESISTANCE TEST AND
CAPACITOR VOLTAGE TEST
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
This test will determine if the primary power board has any “shorted” or “leaky” power diodes
or Insulated Gate Bipolar Transistors (IGBTs). Also it will help to indicate any “shorted” input
filter capacitors.
MATERIALS NEEDED
Analog voltmeter/ohmmeter (multimeter)
Wiring Diagram
7/16” Wrench
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TROUBLESHOOTING & REPAIR
F-15 F-15
PRO-CUT 80
WARNING
This procedure takes approximately 25 minutes to perform.
Page 56
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TROUBLESHOOTING & REPAIR
F-16 F-16
PRO-CUT 80
PRIMARY POWER BOARD RESISTANCE TEST AND
CAPACITOR VOLTAGE TEST (continued)
FIGURE F.3 – PRIMARY POWER BOARD REMOVAL
+
+
CAPACITOR (C2)
TERMINALS
CAPACITOR (C1)
TERMINALS
PRO-CUT 80 POWER G3440 - 1
203 206
207 202
201
204
205
208
TEST PROCEDURE
1. Remove main input power to the PROCUT 80.
2. Perform the Input Filter Capacitor
Discharge Procedure detailed earlier in
this section.
3. Locate the primary power board and asso-
ciated lead locations. See Figure F.3.
4. Carefully remove the main transformer primary leads #201, #204, #205 and #208
from the power board.
5. Use the analog ohmmeter to perform the
test outlined in Table F.2.
Primary power
board with input
filter capacitors
Page 57
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TROUBLESHOOTING & REPAIR
F-17 F-17
PRO-CUT 80
PRIMARY POWER BOARD RESISTANCE TEST AND
CAPACITOR VOLTAGE TEST (continued)
TEST POINT TERMINALS ANALOG METER X10 RANGE
+ Probe - Probe Acceptable Meter Readings
201 207A Greater than 1000 ohms
207A 201 Less than 100 ohms
204 207A Greater than 1000 ohms
207A 204 Less than 100 ohms
202A 204 Greater than 1000 ohms
204 202A Less than 100 ohms
202A 201 Greater than 1000 ohms
201 202A Less than 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 Greater than 1000 ohms
205 206 Less than 100 ohms
TABLE F.2
PRIMARY POWER BOARD RESISTANCE TEST POINTS
6. If the power board does not meet the
acceptable readings outlined in Table F.2,
the board is faulty. Replace. See Power
Board Removal and Replacement
Procedure.
NOTE: Complete power board and filter
capacitor replacement is recommended.
7. If the power board “passes” the resistance
test, the IGBT portion of the board is good.
However, other circuits on the power board
may be faulty. These circuits are NOT readily tested or serviceable.
8. Carefully reconnect leads #201, #204, #205,
and #208 to their appropriate terminals.
Torque To 75 IN. LBS.
Page 58
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TROUBLESHOOTING & REPAIR
F-18 F-18
PRO-CUT 80
PRIMARY POWER BOARD RESISTANCE TEST AND
CAPACITOR VOLTAGE TEST (continued)
CAPACITOR VOLTAGE TEST
This test will help the technician to determine if
the input filter capacitors are being charged
equally to the correct voltage levels.
NOTE: This test should only be conducted with
the PRO-CUT 80 connected for 400 VAC or
above, and with the appropriate input voltage
applied.
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 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 applied to the PRO-CUT
80. BE CAREFUL. ALWAYS REMOVE
THE INPUT POWER AND PERFORM THE
INPUT FILTER CAPACITOR DISCHARGE
PROCEDURE BEFORE TOUCHING ANY
MACHINE COMPONENT.
ELECTRIC SHOCK can kill.
• Have an electrician install and
service this equipment.
• Turn the input power off at the
fuse box before working on
equipment.
• Do not touch electrically hot parts.
5. Apply the correct input power†and turn ON
the PRO-CUT 80.
†
NOTE: This test should only be conducted
with the PRO-CUT 80 reconnect
switch and “A” jumper configured for
400 VAC and above.
WARNING
Page 59
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TROUBLESHOOTING & REPAIR
F-19 F-19
PRO-CUT 80
6. Check for the appropriate voltages outlined
in Table F.3.
NOTE: Voltages may vary with the input line
voltage.
NOTE: If the capacitor voltage is too high
(over 400 VDC) or too low (less than 220
VDC) the control board will deactivate relay
CR1 + CR2. This will prevent output.
7. If the test voltages do not meet the expected values as listed in Table F.3, the capacitors or other components on the power
board may be faulty. Replace.
NOTE: If the capacitor voltages are NOT balanced within 20 VDC, the capacitors may need
“conditioning.” See the Maintenance section.
PRIMARY POWER BOARD RESISTANCE TEST AND
CAPACITOR VOLTAGE TEST (continued)
EXPECTED VOLTS
DC AT CAPACITOR
INPUT APPLIED TERMINALS
460VAC 325VDC
440VAC 311VDC
415VAC 293VDC
380VAC 269VDC
TABLE F.3 - CAPACITOR VOLTAGES
NOTE: If Capacitor C1 is found to be defective, both Capacitors C1 and C2 must be replaced
at the same time. The capacitors must be replaced in matched sets.
Page 60
OUTPUT POWER BOARD RESISTANCE TEST
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
This test will help the technician determine if the output power board is faulty.
MATERIALS NEEDED
5/16” Nut driver
Analog Volt/ohmmeter
7/16” Wrench
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TROUBLESHOOTING & REPAIR
F-20 F-20
PRO-CUT 80
WARNING
This procedure takes approximately 18 minutes to perform.
Page 61
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TROUBLESHOOTING & REPAIR
F-21 F-21
PRO-CUT 80
OUTPUT POWER BOARD RESISTANCE TEST (continued)
FIGURE F.4 – OUTPUT POWER BOARD LEAD LOCATIONS
TEST PROCEDURE
1. Remove input power to the PRO-CUT 80
machine.
2. Perform the Input Filter 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 board. See Figure F.4.
5. Using the analog ohmmeter, perform the
resistance checks per Table F.4.
G3439 PRO-CUT 80 OUTPUT
LED1
LED2
D29
LED4
LED3
LED5
J33 J31 J34 J32 J30
X20
X40
X4 X2
(B12) (B11)
(B21)
TEST POINT
+
C13
D25
TEST POINT
Page 62
6. If any of the resistance checks are not correct, the
output power board is faulty. Replace. See the
Output Power Board Removal and Replacement
Procedure.
7. If the output power board “passes” the resistance
test, the power diode and transistor portion of the
board is good. However, other circuits on the
power board may be faulty. These circuits are NOT
readily tested or serviceable.
8. Carefully reconnect the leads and plugs previously
removed. Torque X2, X4, and B21 to 75 IN. LBS.
TROUBLESHOOTING & REPAIR
F-22 F-22
PRO-CUT 80
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TABLE F.4 - OUTPUT POWER BOARD RESISTANCE
CIRCUIT OR
TEST POINTS COMPONENT(S) EXPECTED RESISTANCE
BEING TESTED
+Probe J33-Pin4 Diode A1 Less than
to and 100 ohms
–Probe Terminal X2 associated 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 Terminal X4 Diode A1 Greater than
to and 1000 ohms
–Probe J33-Pin4 associated trace
+Probe D29 Test Point Diode A2 Less than
to and 100 ohms
–Probe Terminal X20 associated trace
+Probe Terminal X20 Diode A2 Greater than
to and 1000 ohms
–Probe D29 Test Point associated trace
+Probe D29 Test Point Diode A2 Less than
to and 100 ohms
-Probe Terminal X40 associated trace
+Probe Terminal X40 Diode A2 Greater than
to and 1000 ohms
–Probe D29 Test Point associated trace
+Probe D29 Test Point Transistor A2 Less than
to and 100 ohms
–Probe J32-Pin14 associated trace
+Probe J32-Pin14 Transistor A2 Greater than
to and 1000 ohms
–Probe D29 Test Point associated trace
OUTPUT POWER BOARD RESISTANCE TEST (continued)
Page 63
TORCH CONTINUITY AND SOLENOID TEST
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
This procedure will help the technician determine if the torch cable, consumables and electrode solenoid are functioning properly.
MATERIALS NEEDED
Volt/ohmmeter
12 VDC @ 1 Amp Power Supply
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TROUBLESHOOTING & REPAIR
F-23 F-23
PRO-CUT 80
WARNING
This procedure takes approximately 15 minutes to perform.
Page 64
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TROUBLESHOOTING & REPAIR
F-24 F-24
PRO-CUT 80
TORCH CONTINUITY AND SOLENOID TEST (continued)
TEST PROCEDURE
1. Remove input power to the PRO-CUT 80
machine.
2. Remove the torch assembly from the
machine.
3. Using the ohmmeter, check the torch resistances per Table F.5.
NOTE: Take the “Pin” test point measurements
at the machine end of the torch assembly. See Figure F.5.
4. If any of the resistance checks are not correct, the torch assembly may be faulty.
Repair or replace.
5. Carefully apply the 12 VDC supply to the
electrode solenoid. (positive to Pin 2 and
negative to Pin 3). The electrode solenoid
should activate. Listen for the solenoid
action in the torch handle. If the solenoid
does not activate, it may be faulty. Replace.
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 Parallel pilot arc 1.5 ohms maximum None
leads
Pin 7 to Torch One pilot arc lead to 1.0 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 minimum Torch trigger NOT
pulled (not activated)
Pin 1 to Pin 9 Torch trigger circuit 1.0 ohm maximum Torch trigger pulled
(activated)
Pin 2 to Pin 3 Electrode Solenoid 45 to 55 ohms None
Pin 7 to Torch Pilot and Electrode 1.0 ohm maximum Torch consumables
Electrode at machine circuit in place
end of torch
Pin 8 to Torch Pilot and Electrode 1.0 ohm maximum Torch consumables
Electrode at machine circuit in place
end of torch
Page 65
AIR/GAS SOLENOID TEST
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
This procedure will help the technician determine if the solenoid is functioning properly.
MATERIALS NEEDED
5/16” Nut driver
12 VDC @ 3 amp supply
Volt/ohmmeter
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TROUBLESHOOTING & REPAIR
F-25 F-25
PRO-CUT 80
WARNING
This procedure takes approximately 13 minutes to perform.
Page 66
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TROUBLESHOOTING & REPAIR
F-26 F-26
PRO-CUT 80
AIR/GAS SOLENOID TEST (continued)
TEST PROCEDURE
1. Remove input power to the machine.
2. Perform the Input Capacitor Discharge
Procedure detailed earlier in this section.
3. Locate the air solenoid and leads. See Figure
F.6.
4. Carefully remove plug J31 from the output
power board. See Figure F.7.
5. Check the coil resistance of the solenoid at
plug J31 pin-6 to J31 pin-5. Normal resistance is approximately 20 ohms. If the resistance is abnormal, check the continuity (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 the
solenoid leads at plug J31 (positive to J31
pin-6 lead #366 and negative to J31 pin-5
lead #361).
With proper air pressure applied, the solenoid should activate and air should flow.
If the solenoid activates but air does not
flow, check for a restriction in the air line.
7. Install plug J31 back into the output power
board.
FIGURE F.6 – AIR SOLENOID
G3439 PRO-CUT 80 OUTPUT
LED1
LED2
D29
LED4
LED3
LED5
J33 J31 J34 J32 J30
X20
X40
X4 X2
(B12) (B11)
(B21)
TEST POINT
+
C13
D25
TEST POINT
FIGURE F.7 – PLUG J31 LOCATION
Page 67
(T2) AUXILIARY TRANSFORMER TEST
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
The test will determine if the auxiliary transformer is functional when the correct primary voltage is applied to the primary winding.
MATERIALS NEEDED
Volt/ohmmeter
Machine wiring diagram
5/16” Nut driver
230 VAC isolated power supply
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TROUBLESHOOTING & REPAIR
F-27 F-27
PRO-CUT 80
WARNING
This procedure takes approximately 18 minutes to perform.
Page 68
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TROUBLESHOOTING & REPAIR
F-28 F-28
PRO-CUT 80
(T2) AUXILIARY TRANSFORMER TEST (continued)
FIGURE F.8 – T2 AUXILIARY TRANSFORMER
PROCEDURE
1. Remove main input power to the PRO-CUT
80 machine.
2. Perform the Input Filter Capacitor
Discharge Procedure detailed earlier in this
section.
3. Locate the auxiliary transformer. See Fig. F.8
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
(see wiring diagram) and H3 (2J22) of the
auxiliary transformer.
6. Carefully check for the presence of the following primary and secondary voltages at the
appropriate leads at plugs J21 and J22. See
Figure F.8 and Table F.6..
6
1
7
2
8
3
9
4
5
10 PIN
Plug J21
8 PIN
5
1
2
7
8
4
Plug 22
D1
AUXILIARY
TRANSFORMER
H3
H6H5
H4
H2
Page 69
7. If the correct test voltages are present, the
auxiliary transformer is good.
8. If any of the voltages are missing or very low
with the proper primary voltage applied, the
auxiliary transformer may be faulty.
9. If the auxiliary transformer tests good but it
does not function when connected to the
PRO-CUT 80, check 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
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(T2) AUXILIARY TRANSFORMER TEST (continued)
TEST POINT TEST POINT EXPECTED VOLTAGE
H1 H2 (5J22) 200 - 208VAC
H1 H4 (7J22) 380 - 415VAC
H1 H5 (8J22) 440 - 460VAC
Brown (8J21) Brown (3J21) 12VAC
Red (2J21) Red (6J21) 24VAC
Blue (9J21) White (5J21) 18VAC
Blue (4J21) White (5J21) 18VAC
Yellow (1J21) Yellow (7J21) 115VAC
TABLE F.6 - J21 AND J22 VOLTAGES
Page 70
TRIGGER CIRCUIT TEST
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
The procedure will help the technician determine if there is a problem or “fault” in the internal trigger circuit.
MATERIALS NEEDED
Ohmmeter/voltmeter (multimeter)
5/16” Nut driver
Simplified Trigger Circuit Diagram
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TROUBLESHOOTING & REPAIR
F-30 F-30
PRO-CUT 80
WARNING
This procedure takes approximately 19 minutes to perform.
Page 71
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TROUBLESHOOTING & REPAIR
F-31 F-31
PRO-CUT 80
TRIGGER CIRCUIT TEST (continued)
FIGURE F.9 – SIMPLIFIED TRIGGER CIRCUIT DIAGRAM
9
1
#4
#2
1J31
2J31
+17VDC
3J32
#344
TORCH
RECEPTACLE
11J3
+15VDC
TRIGGER SWITCH
IN TORCH HANDLE
OUTPUT BOARD CONTROL BOARD
P
R
O
C
E
S
S
O
R
SIMPLIFIED TRIGGER CIRCUIT
#312
12J3
COM COMAUX
D25
14J32
PROCEDURE
1. Remove input power to the PRO-CUT 80
machine.
2. Perform the Input Filter Capacitor
Discharge Procedure detailed earlier in this
section.
3. Locate the torch cable receptacle and leads
#2 and #4. See Figure F.9, the Simplified
Trigger Circuit Diagram. These leads are best
accessed at plug J31 on the output board.
See Figure F.10.
4. Using the ohmmeter, check for continuity
(less than one ohm) from lead #2 to lead #4.
The torch trigger must be pulled and all input
power removed from the machine. If continuity (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
torch trigger is pulled), proceed to the next
step. Also see Output Board LED
Definitions and related figures.
6. Apply the correct input power to the PROCUT 80. Carefully check for approximately
17 VDC from plug J31 pin-1(lead#4) (positive)
to plug J31 pin-2 (lead#2) (negative). See
Figure F.10. If the correct voltage is not present, perform the Low Voltage Circuit Test.
Also see Output Board LED Definitions and
related figures.
7. If the correct voltage is present in Step 6,
carefully check for the presence of approximately 15 VDC from plug J32 pin-3
(lead#354) (positive) to plug J32 pin-14
(lead#312) (negative). See Figure F.10. Also
see Control Board LED Definitions and
related figures. If the correct voltage is not
present, perform the Low Voltage Circuit
Test.
8. If the correct voltage is present in the above
test, carefully pull the torch trigger.
PILOT ARC, CUTTING ARC, AND HIGH VOLT-
AGE MAY BE PRESENT AT THE
TORCH HEAD. Perform this test
with the air input removed to avoid
a pilot arc at the torch.
WARNING
Page 72
9. With the torch trigger activated check the
voltage at plug J32 pin-3 (lead#354) (positive) to plug J32 pin-14 (lead#312) (negative). Normal is less than 1 VDC. If more
than 1 VDC is indicated, the power output
board may be faulty. Release (deactivate)
the torch trigger and remove input power to
the PRO-CUT 80.
10. Perform the Input Filter Capacitor
Discharge Procedure.
11. Check the continuity of leads #354 and
#312 between the output board and the
control board. See Figure F.9, the
Simplified Trigger Circuit Diagram, and
Figure F.10.
12. If all of the above checks are OK, the control board may be faulty. Replace.
TROUBLESHOOTING & REPAIR
F-32 F-32
PRO-CUT 80
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TRIGGER CIRCUIT TEST (continued)
Page 73
TROUBLESHOOTING & REPAIR
F-33 F-33
PRO-CUT 80
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TRIGGER CIRCUIT TEST (continued)
G3439 PRO-CUT 80 OUTPUT
LED1
LED2
D29
LED4
LED3
LED5
J33 J31 J34 J32 J30
X20
X40
X4 X2
(B12) (B11)
(B21)
TEST POINT
+
C13
D25
TEST POINT
FIGURE F.10 - OUTPUT BOARD TRIGGER CIRCUIT TEST POINTS AND LEDS
PRO-CUT 80 OUTPUT BOARD
LED DEFINITIONS
LED1: (Red) This light indicates that 24 VAC is
being supplied to the output board from the auxiliary transformer. It also shows that the 24 VAC
is being rectified to approximately 32 VDC. This
DC voltage is used for the "parts-in-place"
check for the torch circuit.
LED2: (Red) This light indicates that 12 VAC is
being supplied to the output board from the auxiliary transformer. It also shows that the 12 VAC
is being rectified to approximately 17 VDC. This
DC voltage is used to power the trigger circuit
and solenoid driver circuits incorporated on the
output board.
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) This light indicates that the trigger circuit on the output board has been activated. This LED should be lit when the torch or
remote trigger is closed. This trigger circuit, on
the output board, then sends a signal to the
control board.
LED5: (Green) This light indicates that the electrode solenoid driver circuit is functioning. When
this light is lit, the electrode solenoid should be
activated. The electrode solenoid should be
energized during gas (air) pre-flow time. During
pilot and cutting arc periods, the LED should be
off. When the arc goes out, the machine enters
the post-flow state. Two seconds after the start
of post-flow the electrode solenoid is activated a
few times. The LED should blink to indicate this
activity. The electrode solenoid will then be
energized for the duration of post-flow. (The LED
should be on.)
Page 74
CONTROL BOARD LED DEFINITIONS
LED1: (Red) This light indicates that 18 VAC is
being supplied to the control board from the
auxiliary transformer. It also shows that the 18
VAC is being rectified and should be regulated to
+15 VDC. This +15 VDC supply is used to power
the circuitry on the control board.
LED2: (Red) This light indicates that the +5.5
VDC is present. This voltage is derived from the
+15 VDC supply. The +5.5 VDC supply is used
to power the circuitry on the control board.
LED3: (Red) This light indicates that 18 VAC is
being supplied to the control board from the
auxiliary transformer. It also shows that the 18
VAC is being rectified and should be regulated to
-15 VDC. This -15 VDC supply is used to power
the circuitry on the control board.
TROUBLESHOOTING & REPAIR
F-34 F-34
PRO-CUT 80
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TRIGGER CIRCUIT TEST (continued)
PRO-CUT 55 CONTROL G3328
LED2
LED1
LED3
FIGURE F.11 - CONTROL BOARD LEDs
PRO-CUT 80 CONTROL G3443
Page 75
LOW VOLTAGE CIRCUIT TEST
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
These voltage checks will help the technician determine if the correct voltages are being
applied and processed by the various P.C. boards. Some of the voltage verification test
points are not easily accessible. The presence of these voltages can also be confirmed by
LEDs on the various P.C. boards.
MATERIALS NEEDED
5/16” Nut driver
Volt/ohmmeter (multimeter)
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TROUBLESHOOTING & REPAIR
F-35 F-35
PRO-CUT 80
WARNING
This procedure takes approximately 20 minutes to perform.
Page 76
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TROUBLESHOOTING & REPAIR
F-36 F-36
PRO-CUT 80
FIGURE F.12 - LOW VOLTAGE CIRCUIT DIAGRAM
#216
#219
15J40
10J40
6J2
9J2
#61
#62
#64
1J1
2J1
4J1
#54
#51
#56
#53
4J30
1J30
6J30
3J30
4
5
9
6
2
3
8
BROWN
BROWN
RED
RED
BLUE
WHITE
BLUE
H1
H2
H3
H4
H5
24VAC
12VAC
18VAC
18VAC
T2 AUXILIARY
TRANSFORMER
CONTROL BOARD
PLASMA
OUTPUT
BOARD
D
I
S
P
L
A
Y
B
O
A
R
D
+15VDC
+
TO
RECONNECT
LEAD "A"
TO H1
"C" TERMINAL
INPUT
RECTIFIER
J21
=17VDC
=28VDC
=+15VDC
=-15VDC
LOW VOLTAGE CIRCUIT TEST (continued)
PROCEDURE
1. Remove input power to the PRO-CUT 80
machine.
2. Using the 5/16" nutdriver remove the case
wraparound cover.
ELECTRIC SHOCK can kill.
• Do not touch electrically hot parts.
3. Apply the correct input power to the machine
and carefully check for the following voltages.
4. Check for the presence of approximately 32
VDC on the output board.
a. LED1 should be lit when 32 VDC is present.
See Figure F.13. See Output 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 leads. See Figure F.13.
5. Check for the presence of 17 VDC on the output board.
a. LED2 should be lit when 17 VDC is present.
See Figure F.13. See Output Board LED
Definitions and Figure F.12, Low Voltage
Circuit Diagram.
b. To verify the presence of 17 VDC, check
from plug J31 Pin-6 to diode D25 (anode).
See Figure F.13. Make certain the volt-
meter probes make good contact with pin6 and the diode anode lead. It will be necessary to penetrate the silicon sealant.
6. Check for the presence of +15 VDC on the
control board.
a. LED1 should be lit when +15 VDC is pre-
sent. See Figure F.13. See Control
Board LED Definitions and Figure F.12,
Low Voltage Circuit Diagram.
7. Check for the presence of -15 VDC on the control board.
a. LED3 should be lit when -15 VDC is pre-
sent. See Figure F.13. See Control Board
LED Definitions and Figure F.12, Low
Voltage Circuit Diagram.
WARNING
17 VDC
32 VDC
Page 77
8. Check for the presence of +5 VDC on the
control board.
a. LED2 should be lit when +5 VDC is pre-
sent. See Figure F.14. See Control Board
LED Definitions and Figure F.12, Low
Voltage Circuit Diagram.
9. Check for the presence of +15 VDC being
applied to the display board from the control
board. You may have to remove the display
board to check it.
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 missing, make certain the correct AC supply voltages are being applied to the P.C.
boards. See Figure F.12, Low Voltage
Circuit Diagram and (T2) Auxiliary
Transformer Test.
11.
When the test is complete, remove input
power and replace the case wraparound cover.
TROUBLESHOOTING & REPAIR
F-37 F-37
PRO-CUT 80
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Page 78
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TROUBLESHOOTING & REPAIR
F-38 F-38
PRO-CUT 80
FIGURE F.13 – OUTBOARD LOW VOLTAGE CIRCUIT TEST POINTS AND LEDs
G3439 PRO-CUT 80 OUTPUT
LED1
LED2
D29
LED4
LED3
LED5
J33 J31 J34 J32 J30
X20
X40
X4 X2
(B12) (B11)
(B21)
TEST POINT
+
C13
D25
TEST POINT
LOW VOLTAGE CIRCUIT TEST (continued)
PRO-CUT 80 OUTPUT BOARD
LED DEFINITIONS
LED1: (Red) This light indicates that 24 VAC is
being supplied to the output board from the auxiliary transformer. It also shows that the 24 VAC
is being rectified to approximately 28 VDC. This
DC voltage is used for the "parts-in-place"
check for the torch circuit.
LED2: (Red) This light indicates that 12 VAC is
being supplied to the output board from the auxiliary transformer. It also shows that the 12 VAC
is being rectified to approximately 17 VDC. This
DC voltage is used to power the trigger circuit
and solenoid driver circuits incorporated on the
output board.
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) This light indicates that the trigger circuit on the output board has been activated. This LED should be lit when the torch or
remote trigger is closed. This trigger circuit, on
the output board, then sends a signal to the
control board.
LED5: (Green) This light indicates that the electrode solenoid driver circuit is functioning. When
this light is lit, the electrode solenoid should be
activated. The electrode solenoid should be
energized during gas (air) pre-flow time. During
pilot and cutting arc periods, the LED should be
off. When the arc goes out, the machine enters
the post-flow state. Two seconds after the start
of post-flow the electrode solenoid is activated a
few times. The LED should blink to indicate this
activity. The electrode solenoid will then be
energized for the duration of post-flow. (The LED
should be on).
Page 79
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TROUBLESHOOTING & REPAIR
F-39 F-39
PRO-CUT 80
LOW VOLTAGE CIRCUIT TEST (continued)
CONTROL BOARD LED DEFINITIONS
LED1: (Red) This light indicates that 18 VAC is
being supplied to the control board from the
auxiliary transformer. It also shows that the 18
VAC is being rectified and should be regulated to
+15 VDC. This +15 VDC supply is used to power
the circuitry on the control board.
LED2: (Red) This light indicates that the +5.5
VDC is present. This voltage is derived from the
+15 VDC supply. The +5.5 VDC supply is used
to power the circuitry on the control board.
LED3: (Red) This light indicates that 18 VAC is
being supplied to the control board from the
auxiliary transformer. It also shows that the 18
VAC is being rectified and should be regulated to
-15 VDC. This 15 VDC supply is used to power
the circuitry on the control board.
FIGURE F.14 – CONTROL BOARD LEDs
FIGURE F.15 – DISPLAY BOARD TEST POINTS
PRO-CUT 55 CONTROL G3328
LED2
LED1
LED3
L10721 DISPLAY BOARD
(REAR VIEW)
J 40
1
15
#219
#216
PRO-CUT 80 CONTROL G3443
Page 80
CONTROL BOARD REMOVAL AND REPLACEMENT
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
The following procedure will aid the technician in removing the control board for maintenance
or replacement.
MATERIALS NEEDED
5/16” Nut driver
Needle-nose pliers
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TROUBLESHOOTING & REPAIR
F-40 F-40
PRO-CUT 80
WARNING
This procedure takes approximately 15 minutes to perform.
Page 81
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TROUBLESHOOTING & REPAIR
F-41 F-41
PRO-CUT 80
PROCEDURE
1. Remove input power to the PRO-CUT 80
machine.
2. Remove the wraparound cover and perform
the Input Filter 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.16.
4. Carefully slide (do not force) the front away
from the rest of the machine about one inch.
This will allow more “working” room to
remove the control board.
CONTROL BOARD REMOVAL AND REPLACEMENT (continued)
CONTROL
BOARD
MOLEX PLUGS (5)
FIGURE F.16 - CASE FRONT SCREW REMOVAL
FIGURE F.17 - CONTROL BOARD MOLEX PLUG REMOVAL
4 Screws
Page 82
5. Locate the control board and the five molex
type plugs connected to it. See Figure F.17.
6. Carefully remove the five molex type plugs by
depressing the locking tabs and gently
extracting the plugs from the P.C. board
receptacles.
7. Using the needle-nose pliers and screwdriver, gently remove the control board from the
eight mounting pins by depressing the tabs
on the mounting pins and carefully removing
the board from the pins. See Figure F.18.
Be sure to follow the recommended static-free
methods for handling printed circuit boards.
Failure to do so can result in permanent damage
to the equipment.
8. When replacing the control board, align the
mounting holes with the eight mounting pins
and gently slide the 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 are
securely in place.
10. Carefully reposition the front assembly in
place and install the four mounting screws
previously removed.
11. Inspect, clear and secure all leads before
installing the case wrap-around reassembly.
12. Using the 5/16” nut driver, install the case
wraparound.
TROUBLESHOOTING & REPAIR
F-42 F-42
PRO-CUT 80
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FIGURE F.18 - CONTROL BOARD REMOVAL FROM MOUNTING PINS
CONTROL BOARD REMOVAL AND REPLACEMENT (continued)
CAUTION
DEPRESS
LOCKING TAB ON
MOUNTING PIN
CONTROL
BOARD
MOUNTING
PIN (8)
Page 83
DISPLAY BOARD REMOVAL AND REPLACEMENT
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call or 1-800-833-9353 (WELD).
DESCRIPTION
The following procedure will aid the technician in removing the display board for maintenance
or replacement.
MATERIALS NEEDED
5/16” Nut driver
Screw driver
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TROUBLESHOOTING & REPAIR
F-43 F-43
PRO-CUT 80
WARNING
This procedure takes approximately 15 minutes to perform.
Page 84
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TROUBLESHOOTING & REPAIR
F-44 F-44
PRO-CUT 80
PROCEDURE
1. Remove the input power to the PRO-CUT 80
machine.
2. Remove 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 top
and base of the machine. See Figure F.19.
4. Carefully slide (do not force) the front away
from the rest of the machine about one inch.
This will allow more “working” room to
remove the display board.
DISPLAY BOARD REMOVAL & REPLACEMENT (continued)
FIGURE F.19 - CASE FRONT SCREW REMOVAL
4 Screws
Page 85
5. Locate the display P.C. board and the one
plug connected to it. See Figure F.20.
6. Gently remove the display P.C. board from
the three mounting pins.
Be sure to follow the recommended static-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.
8. When replacing the display board, carefully
connect the plug into the board. Make certain 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 place.
10. Carefully reposition the front assembly in
place and install the four mounting screws
previously removed.
11. Inspect, clear and secure all leads in preparation for the case wraparound reassembly.
12. Using the 5/16” nut driver, install the case
wraparound.
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TROUBLESHOOTING & REPAIR
F-45 F-45
PRO-CUT 80
FIGURE F.20 – DISPLAY BOARD REMOVAL
CASE FRONT
DISPLAY BOARD
DISPLAY BOARD REMOVAL & REPLACEMENT (continued)
CAUTION
Page 86
OUTPUT POWER BOARD REMOVAL AND REPLACEMENT
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
The following procedure will aid the technician in removing the output power board for maintenance or replacement.
MATERIALS NEEDED
5/16” Nut driver
3/16” Allen type wrench
7/16” Wrench
Penetrox A-13 (Lincoln E2529) Electrical Joint Compound
Phillips head screw driver
Torque wrench
TROUBLESHOOTING & REPAIR
F-46 F-46
PRO-CUT 80
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WARNING
This procedure takes approximately 25 minutes to perform.
Page 87
TROUBLESHOOTING & REPAIR
F-47 F-47
PRO-CUT 80
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FIGURE F.21 – OUTPUT POWER BOARD REMOVAL
OUTPUT POWER BOARD REMOVAL & REPLACEMENT (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. Locate the output power P.C. board and
associated lead and plug connections. See
Figures F.21 and F.22.
OUTPUT POWER BOARD
Page 88
TROUBLESHOOTING & REPAIR
F-48 F-48
PRO-CUT 80
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FIGURE F.22 – OUTPUT BOARD LEAD LOCATIONS
G3439 PRO-CUT 80 OUTPUT
LED1
LED2
D29
LED4
LED3
LED5
J33 J31 J34 J32 J30
X20
X40
X4 X2
(B12) (B11)
(B21)
TEST POINT
+
C13
D25
TEST POINT
OUTPUT POWER BOARD REMOVAL & REPLACEMENT (continued)
4. Using the 7/16” wrench, remove leads X4, X2
and B21 from the output power board.
5. Remove plugs J30, J31, J32, 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 corners of the output power board.
8. Using the 3/16” allen head wrench, remove
the four socket screws mounting the output
power board to the heat sink.
9. Carefully remove the output power board
from the heat sink.
Be sure to follow the recommended static-free
methods for handling printed circuit boards.
Failure to do so can result in permanent damage
to the equipment.
CAUTION
Page 89
REPLACEMENT PROCEDURE
1. Apply a thin coating of Penetrox A-13
Electrical Joint Compound to the mating surfaces of the output power board and the heat
sink. Make sure the surfaces are clean. Do
not allow the compound to get into the
threaded holes or on the screw threads.
Be sure to follow the recommended static-free
methods for handling printed circuit boards.
Failure to do so can result in permanent damage
to the equipment.
2. Mount the output power board to the heat
sink and pre-torque the four socket head
screws to 25 inch-pounds.
3. Finish tightening the four screws to 40-48
inch-pounds.
4. Replace the four phillips head screws previously removed.
5. Replace leads X20 and X40.
6. Replace plugs J30, J31, J32, J33, and J34.
7. Replace leads X4 and X2, then torque to 75
IN. LBS.
8. Replace lead B21 and torque it to 75 IN. LBS.
9. Clear and secure all leads and replace the
wraparound cover.
TROUBLESHOOTING & REPAIR
F-49 F-49
PRO-CUT 80
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CAUTION
Page 90
PRIMARY POWER BOARD AND FILTER CAPACITOR
REMOVAL AND REPLACEMENT
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
The following procedure will aid the technician in removing the primary power board and filter capacitors for maintenance or replacement.
MATERIALS NEEDED
5/16” Nut driver
3/16” Allen type wrench
7/16” Wrench
Phillips Head screw driver
Torque wrench
3/8” Wrench
Penetrox A-13 (Lincoln E2529) Electrical Joint Compound
TROUBLESHOOTING & REPAIR
F-50 F-50
PRO-CUT 80
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WARNING
This procedure takes approximately 40 minutes to perform.
Page 91
TROUBLESHOOTING & REPAIR
F-51 F-51
PRO-CUT 80
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FIGURE F.23 – PRIMARY POWER BOARD REMOVAL
PRIMARY POWER BOARD AND FILTER CAPACITOR
REMOVAL AND REPLACEMENT (continued)
REMOVAL PROCEDURE
1. Remove input power from the PRO-CUT 80
machine.
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 associated lead and plug connections. See Figure
F.23.
4. Label the leads for reassembly.
5. Remove Plug J10 and any necessary cable
ties.
6. Using the 7/16” wrench, remove leads 201,
202, 203, 204, 205, 206, 207, 208 and 209.
Primary Power
Board With Input
Filter Capacitors
Page 92
TROUBLESHOOTING & REPAIR
F-52 F-52
PRO-CUT 80
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FIGURE F.24 – POWER BOARD HEATSINK AND CAPACITOR REMOVAL
PRIMARY POWER BOARD AND FILTER CAPACITOR
REMOVAL AND REPLACEMENT (continued)
7. Using the Phillips Head screw driver, remove
the two mounting screws from the top right of
the primary power board. See Figure F.24.
8. Using the 3/16” allen type wrench, remove
the eight socket head screws and lock washers mounting the primary power board to the
heat sink.
9. Carefully remove the primary power board
from the heat sink.
Be sure to follow the recommended static-free
methods for handling printed circuit boards.
Failure to do so can result in permanent damage
to the equipment.
CAUTION
Heatsink Mounting
Screws (4)
Mounting
Screws (2)
Socket Head
Screws (8)
Page 93
CAPACITOR REMOVAL
1. Using the 3/8” wrench, remove the four
screws holding the heat sink to the center
panel assembly. Take note of the insulator
placement for reassembly. The four screws
have insulating washers on both sides of the
panel assembly. These must be properly
replaced upon reassembly.
2. Carefully push the heat sink in towards the
center of the machine. This is necessary to
gain clearance for capacitor(s) removall.
3. Carefully slide the capacitor(s) from the heat
sink assembly. Observe polarity markings
and terminal position.
CAPACITOR REPLACEMENT AND
P.C. BOARD REPLACEMENT
1. Carefully slide the new capacitor(s) into the
heat sink assembly.
2. Reassemble the heat sink assembly to the
center panel using the four screws and insu
lated washers previously removed. Note
insulation placement.
3. Position the capacitors to the P.C.Board for
assembly. Note the polarity of the
capacitors.
4. Apply a thin coating of Penetrox A-13
Electrical Joint Compound to the mating surfaces 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 the capacitor
terminals line up with the holes in the P.C.
board and with the correct capacitor polarities.
6. Assemble the eight socket head screws and
pre-torque them to 25 inch-pounds.
7. Make certain the capacitors are lined up correctly so that when the capacitor bolts are
assembled through the P.C. board, there will
NOT be any distortion to the P.C. board.
8. Finish tightening the eight screws to 40-48
inch-pounds.
9. Assemble the two Phillips Head screws previously removed.
10. Connect the J10 plug.
11. Connect leads 201, 204, 205, 208 and 209
previously removed. Torque to 75 IN. LBS.
12. Connect leads 202A, 207A, 206, and 203A
to the capacitor terminals. Torque to 50-60
inch-pounds.
13. Clear and reposition any leads that may be
disturbed. Replace wire ties.
14. Replace the case wraparound cover.
TROUBLESHOOTING & REPAIR
F-53 F-53
PRO-CUT 80
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PRIMARY POWER BOARD AND FILTER CAPACITOR
REMOVAL AND REPLACEMENT (continued)
Page 94
INPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
The following procedure will aid the technician in removing the input rectifier bridge for maintenance or replacement.
MATERIALS NEEDED
3/16” Allen type wrench
Phillips head screw driver
Torque wrench
Penetrox A13 (Lincoln E2529) Electrical Joint Compound
Dow Corning 738 (Lincoln E2861) Electrical Insulating Compound
TROUBLESHOOTING & REPAIR
F-54 F-54
PRO-CUT 80
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WARNING
This procedure takes approximately 16 minutes to perform.
Page 95
TROUBLESHOOTING & REPAIR
F-55 F-55
PRO-CUT 80
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FIGURE F.25 – INPUT RECTIFIER LEAD LOCATIONS
#207A
#207
#209A
B
C
INPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued)
PROCEDURE
1. Remove input power to the PRO-CUT 80.
2. Perform the Input Filter Capacitor
Discharge Procedure detailed earlier in this
section.
3. Locate the input rectifier and the leads connected to it. See Figure F.25.
4. Identify and mark the leads connected to the
rectifier terminals.
5. With the phillips head screw driver, remove
the lead terminals connected to the rectifier
terminals.
6. Using the 3/16” allen wrench, remove the two
cap head screws and washers mounting the
input rectifier bridge to the center panel
assembly.
TOP VIEW
Page 96
TROUBLESHOOTING & REPAIR
F-56 F-56
PRO-CUT 80
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INPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued)
7. Carefully remove the input rectifier bridge.
8. When installing a new input rectifier apply a
thin coating of Penetrox A-13 Heat Sink
Compound (Lincoln E2529) to the mating
surfaces. Torque the mounting cap screws
and nuts to 44 in-lbs.
9.
Reconnect the 10 leads to the correct terminals and torque the phillips head screws
to 31 in-lbs.
10. Apply Dow Corning 738 Insulating Com-
pound to all six screw heads and terminals. The heavy input lead terminals
should be against the rectifier terminals.
11. Assemble case wrap-around cover.
Page 97
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TROUBLESHOOTING & REPAIR
F-57 F-57
PRO-CUT 80
RETEST AFTER REPAIR
Should a machine under test be rejected for any reason requiring the removal of any mechanical part that could
affect the machine’s electrical characteristics, or if any electrical components are repaired or replaced, the
machine must be retested.
INPUT IDLE AMPS AND WATTS
Input Volts/Hertz Idle Amps Idle Watts
208/230/460 0.61 140
Output Current Range 35 - 85 Amps
Maximum Open Circuit Voltage 335 Volts
Page 98
NOTES
F-58 F-58
PRO-CUT 80
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Page 99
G-1
ELECTRICAL DIAGRAMS
G-1
PRO-CUT 80
TABLE OF CONTENTS
-ELECTRICAL DIAGRAMS SECTION-
ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION G
WIRING 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 PC BOARD SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-8
OUTPUT PC BOARD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-9
DISPLAY PC BOARD SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-10
DISPLAY PC BOARD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-11
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Page 100
ELECTRICAL DIAGRAMS
G-2
PRO-CUT 80
WIRING DIAGRAM - PRO CUT 80
1
++VOLT
6
RELAY
12 GND
11 TRIGGER
3 IGBT
2,6 PSI SWITCH
10 ELEC SOL
9 AIR SOL
214
7
210
275
J22
1
216
8
A
H4
TP2
18V
FRONT OF MACHINE
3
8
MAIN
P_XFMR
7
XFMR
202
10
PSI SET
ELEC
XFER
1
1,2 TRIGGER
+
204
4 ELECTRODE
204
208
TRANSFORMER
61
I
64
W
401
J10
P_XFMR
9
2
354
3
5
8
X2
312
7
J3
FOR SINGLE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE.
POWER
CONNECT BLACK & WHITE LEADS TO SUPPLY CIRCUIT.
WRAP RED LEAD WITH TAPE TO PROVIDE 600V. INSULATION.
MOTOR
FOR THREE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE.
CONNECT BLACK, RED & WHITE LEADS TO SUPPLY CIRCUIT.
2. FOR MACHINES NOT SUPPLIED WITH INPUT CABLE
2
FOR SINGLE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES.
CONNECT TERMINALS U & W TO SUPPLY CIRCUIT.
FAN
W
R
W
COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER.
TRANSFORMER
OUTPUT
COLOR CODE:
B = BLACK
G = GREEN
R = RED
U = BLUE
PROTECTIVE BONDING CIRCUIT
N = BROWN
62
U
3000/450
C1
506
505
Y
Y
404
FAN
FAN
W = WHITE
203
H3
54
203
Y = YELLOW
H2
CASE FRONT
404
S4 PRIMARY RECONNECT
H5
H4
206
NOTES:
N.A.
1. FOR MACHINES SUPPLIED WITH INPUT CABLE
FAN
FR-OUT
202
306
309
AIR
SOLENOID
217
INTERFACE RECEPTACLE
R
W
J4,J10,
J30
Y
54
9
I
R
R
H
H3
210
3
1
N
N
6
R
J1
312
361
T2
B
4
5
51
2
343
344
348
1
C
H1
9
C
5,6 AIR SOL
7,8 ELEC SOL
J32
3 TRIGGER
11
12
4A
2A
ELECTRICAL SYMBOLS PER E1537
J30
L1
354
B
CONNECTOR CAVITY NUMBERING SEQUENCE
2
303
N
7,8 ELEC SHUNT (TWIST PR)
CT
X10
2
W
2
X3
X20
X2
A
3
2
6
18V
-
201
N.A.
PER
365
V
W
15
223
8
12V
N
213
H1
N
24V
U
B
14 GND
13
14
5
1
2
6
3
7
4
2
5
56
53
3
6
440-
E
S
xxxxxxx
N.C. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE.
CONNECTION SHOWN IS FOR 440-460V OPERATION.
N.D. C1 AND C2 CAPACITORS 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
DISPLAY
+
-
6
S
CW (MAX)
276
R1
15
7
R
1
275
221
2
16
277
3
8
W
4
8
6
2
5
3
4
8
309
303
2
5
PC BOARD
276
213
4
9
6
219
215
J40
215
2W
205
501
62
POWER
AUXILIARY
64
GC
401
A
A
0.6A
310
J32
FR-OUT
277A
61
507
FAN
1
415V
S
FR-IN
201
4
B
221
J21
J
344
W
366
FE
G
A
1
7
L10936
5
212
5
10K
216
W
4
2
6
8
16
C
B
N
18V
CONTROL
4,5 XFER SHUNT (TWIST PR)
5
12
13
10
J5
5
3
1
1
3
2
205
ELEC
4
11
3
J33
+
207
POT
277A
Y
Y
7
14
1
8
4
8
1
5
3
6
1
4
2
1
4153
5
10
1
1
XFER
REAR OF MACHINE
E
F
-
207
INPUT
xxxxxxx
3000/450
C2
H6
T3
207A
N.C.
J20
1
306
2
369
4
364
4
J40
6
51
1
220-
200-
230V
208V
OUTPUT
380-
460V
14
223
11
12
348
PRESSURE
L14K
343
212
D
502
FAN
I
1
9
X30
302
E
X40
X4
X40
X20
310
8 AIR SOL
2 ELEC SOL
J34
1,4 24V
X1
10
4
214
8
W
10
219
S
13
S
S
S
115V
Y
TSTAT
8
3 NOZZLE
J31
9
347
6
206
366
203
XL-RW
S
BK-IN
2
R
218
3
S
BK-OUT
217
6
2
7
BK-IN
218
BK-OUT
FR-IN
4A
WORK
2A
M
10 WORK
360
13 IGBT
365
506
505
502
RIGHT SIDE OF MACHINE
8
12V
CHOKE
347
7
S2
RESET
R
S1
53
56
5
207A
7
TP3
TP1
U
H5
Y
B
D1
INPUT
BRIDGE
A
503
6
18V
3
A
D
209
507
501
++VOLT
RELAY
208
202
BASE
FOR THREE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES.
CONNECT TERMINALS U, V & W TO SUPPLY CIRCUIT.
N.B. SINCE COMPONENTS OR CIRCUITRY OF A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING
THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT
RESET LED
THERMAL LED
GND
RESET
POT WIPER
LOW_PSI LED
READY LED
+15V
5
J4
4
2
7
369
360
3
364
E
N
2
4
9
S5
4
10
1
361
5
206
B21
SHOWN FOR 400-460VAC OPERATION
X4
207A
SLOW BLOW
G-2
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NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
G4239
G4238
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