Lincoln Electric PRO-CUT 55 Service Manual
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Lincoln Electric PRO-CUT 55 Service Manual

For use with machine code numbers 10473, 10474
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See also: Operator's Manual
SVM140-A
November, 1998
™
PRO-CUT
55
For use with machine code numbers 10473, 10474
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 READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before
you act and be careful.

SERVICE MANUAL

World's Leader in Welding and Cutting Products
Premier Manufacturer of Industrial Motors
• 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

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  • Page 1: Service Manual

    SVM140-A November, 1998 ™ PRO-CUT For use with machine code numbers 10473, 10474 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 .

  • Page 2: Safety

    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.

  • Page 3: Electric Shock Can Kill

    (MSDS) and follow your 3.j. Also see Items 6.c. and 8. employer’s safety practices. MSDS forms are available from your welding distributor or from the manufacturer. 5.e. Also see item 1.b. PRO-CUT 55...
  • Page 4 This can create fire hazards or overheat lifting chains or Electrical Code, all local codes and the manufacturer’s cables until they fail. recommendations. 6.h. Also see item 1.c. 8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer’s recommendations. PRO-CUT 55...
  • Page 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. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir ttout risque d’incendie dû étincelles. PRO-CUT 55...

  • Page 6: Table Of Contents

    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 ....................P309 Series & P210-K PRO-CUT 55...
  • Page 7 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 PRO-CUT 55...

  • Page 8: Installation

    INSTALLATION TECHNICAL SPECIFICATIONS - PRO-CUT 55 INPUT RATINGS Single Phase Input Input Currents Rated Output Amps Voltage and Hertz 208/1/60 230/1/60 460/1/60 208/1/60 230/1/60 460/1/60 Three Phase Input Input Currents Rated Output Amps Voltage and Hertz 208/3/60 230/3/60 460/3/60 208/3/60...

  • Page 9: Technical Specifications

    INSTALLATION TECHNICAL SPECIFICATIONS (Cont’d) - PRO-CUT 55 GAS REQUIREMENTS Required Gas Flow Rate Required Gas Inlet Pressure 70 PSI @ 360 SCHF 80 to 150 PSI (4.8 Bar. @ 10160 LHR) (5.4 Bar. to 10.2 Bar.) RECOMMENDED INPUT WIRE AND FUSE SIZES For all plasma cutting applications based on U.S.

  • Page 10: Safety Precautions

    A source of clean, dry air or nitrogen must be supplied • If the ground clamp cannot be isolated, then keep the to the Pro-Cut 55. Oil in the air is a severe problem and clamp as far as possible from other work clamp con- must be avoided.

  • Page 11: Input Power Cord Connector Installation

    Before installing the machine, check that input supply voltage, phase, and frequency are the same as the The Pro-Cut 55 is supplied with one 11 foot (3.35m) #8 machine’s voltage, phase, and frequency as specified AWG 3 lead input power cord already connected to on the machine’s rating plate.

  • Page 12: Reconnect Procedure

    INSTALLATION RECONNECT PROCEDURE FIGURE A.2 – RECONNECTION DIAGRAM When received directly from the factory, the machines RECONNECT PROCEDURE are internally connected for 230 VAC. Reconnection will be necessary if a higher input voltage is used. To WARNING reconnect the Pro-Cut to 460 VAC or to connect back to 230 VAC, follow the directions as outlined below.

  • Page 13: Gas Input Connections

    • Flow rate should be approximately 6.0 cfm (170 I/min.). NOTE: Oil in the air supply to the Pro-Cut 55 can cause severe problems. Use only a clean air supply. • Connect the gas supply to the Pro-Cut 55’s pneumatic nipple at the air filter.

  • Page 14: Output Connections

    INSTALLATION OUTPUT CONNECTIONS FIGURE A.4 - TORCH CONNECTION AT CASE FRONT TORCH CONNECTION The Pro-Cut 55 is supplied from the factory with a PCT 80 cutting torch. Additional cutting torches can be XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX ordered from the K1571 series.
  • Page 15 Pilot Arc Considerations ......................B-5 Cutting Operation ........................B-5 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 PRO-CUT 55...

  • Page 16: Operation

    • Keep your body away from nozzle and plasma arc. • Operate the pilot arc with caution. The pilot arc is capable of burning the oper- ator, others, or even piercing safety clothing. Observe additional Safety Guidelines detailed in the beginning of this manual. PRO-CUT 55...

  • Page 17: Operation

    • Air regulator and pressure gauge located on the ages. An undercarriage kit can be ordered separately. front of machine for convenience. The Pro-Cut 55 initiates the plasma arc with a simple, • ”Parts-in-Place” mechanism to detect proper instal- yet reliable, touch-start mechanism. This system elim- lation of consumables and torch.

  • Page 18: Cutting Capability

    OPERATION CUTTING CAPABILITY The Pro-Cut 55 is rated at 55 amps, at 50% duty cycle on a 10 minute basis or 40 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.

  • Page 19: Controls And Settings

    Always keep in mind that the pilot arc is designed to transfer the arc to the work- PRO-CUT 55 piece and not for numerous starts without cutting. When the pilot arc is started, a slight impulse will be felt in the torch handle.
  • Page 20 OPERATION - The gas will immediately turn off. The pressure 5° - 15° Leading Angle 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. •...

  • Page 21: User Responsibility

    OPERATION PREHEAT TEMPERATURE FOR WARNING PLASMA CUTTING ELECTRIC SHOCK can kill. Preheat temperature control is not necessary in most applications when plasma arc cutting or gouging. • Turn off machine at the disconnect Preheat temperature control may be necessary on switch on the front of the machine high carbon alloy steels and heat treated aluminum for before tightening, cleaning or replac-...

  • Page 22: Thick Sections Of Metal

    OPERATION THICK SECTIONS OF METAL 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 Torch Standoff Machine Output Setting the tripping of the Pro-Cut's safety circuit. When this happens, turn the power off, remove the noz- zle and electrode and use the electrode to rub against the inside bottom surface of the nozzle.
  • Page 23 Section C-1 Section C-1 TABLE OF CONTENTS - ACCESSORIES - Accessories...........................Section C Options/Accessories........................C-2 PRO-CUT 55...
  • Page 24 ACCESSORIES • Only Genuine Lincoln Electric consumables yield The following options/accessories are available for the best cutting performance for the Pro-Cut 55. your Pro-Cut 55 from your local Lincoln Distributor. • The patent pending VORTECH™ nozzle provides K1600-1 Undercarriage - A valet style undercarriage an extra “kick”...
  • Page 25 Section D-1 Section D-1 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 PRO-CUT 55...
  • Page 26 MAINTENANCE 4. Obtain a high resistance and high wattage resistor WARNING (25-1000 ohms and 25 watts minimum). This resis- tor is not supplied with machine. NEVER USE A ELECTRIC SHOCK SHORTING STRAP FOR THIS PROCEDURE. can kill. 5. Locate the two capacitor terminals (large hex head •...

  • Page 27: Routine Maintenance

    Replace if necessary by first removing the two screws that attach the filter cage to the back 2. Filter Capacitor Conditioning (Pro-Cut 55, 400-460 panel assembly, then slide the cage away from the VAC only) back of the machine and remove.
  • Page 28 Maintenance FIGURE D.2 – MAJOR COMPONENT LOCATIONS 1. Machine Base 2. Case Front 3. Output Power Board Assembly 4. Case Wraparound 5. Control Board 6. Case Back 7. Primary Power Board 8. Auxiliary Transformer 9. Main Transformer...
  • Page 29 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 FIGURE E.1 – PRO-CUT 55 BLOCK LOGIC DIAGRAM WORK NOZZLE ELECTRODE POWER BOARD TORCH MAIN CONNECTOR...

  • Page 30: Theory Of Operation

    TRANSFORMER GENERAL DESCRIPTION INPUT LINE VOLTAGE, CONTACTOR AND MAIN The Pro-Cut 55 is a constant current, continuous con- TRANSFORMER trol plasma cutting power source. The inverter based power supply design is controlled by a microprocessor The single-phase or three-phase input power of 200- control board.

  • Page 31: Precharge And Protection

    THEORY OF OPERATION FIGURE E.3 – PRECHARGE AND PROTECTION WORK NOZZLE ELECTRODE POWER BOARD TORCH MAIN CONNECTOR CR 1 OUTPUT BOARD TRANSFORMER RELAY INPUT IGBT LINE INPUT SWITCH RECTIFIER CAPACITOR CHOKE PILOT IGBT TRANSISTOR IGBT CURRENT TRANSFORMER TRIGGER & SAFETY CAPACITOR SOLENOID IGBT...

  • Page 32: Main Transformer

    THEORY OF OPERATION FIGURE E.4 – MAIN TRANSFORMER WORK NOZZLE ELECTRODE POWER BOARD TORCH MAIN CONNECTOR CR 1 OUTPUT BOARD TRANSFORMER RELAY INPUT IGBT LINE INPUT SWITCH RECTIFIER CAPACITOR CHOKE PILOT IGBT TRANSISTOR IGBT CURRENT TRANSFORMER TRIGGER & SAFETY CAPACITOR SOLENOID IGBT TRIGGER &...

  • Page 33: Output Board And Torch

    THEORY OF OPERATION FIGURE E.5 – PLASMA OUTPUT BOARD AND TORCH WORK NOZZLE ELECTRODE POWER BOARD TORCH MAIN CONNECTOR CR 1 OUTPUT BOARD TRANSFORMER RELAY INPUT IGBT LINE INPUT SWITCH RECTIFIER CAPACITOR CHOKE PILOT IGBT TRANSISTOR IGBT CURRENT TRANSFORMER TRIGGER & SAFETY CAPACITOR SOLENOID IGBT...

  • Page 34: Control And Display Boards

    THEORY OF OPERATION FIGURE E.6 – CONTROL AND DISPLAY BOARDS WORK NOZZLE ELECTRODE POWER BOARD TORCH MAIN CONNECTOR CR 1 OUTPUT BOARD TRANSFORMER RELAY INPUT IGBT LINE INPUT SWITCH RECTIFIER CAPACITOR CHOKE PILOT IGBT TRANSISTOR IGBT CURRENT TRANSFORMER TRIGGER & SAFETY CAPACITOR SOLENOID IGBT...

  • Page 35: Protection Circuits

    PROTECTION CIRCUITS THERMAL PROTECTION Two thermostats protect the machine from excessive Protection circuits are designed into the Pro-Cut 55 operating temperatures. One thermostat is located on machine to sense trouble and shut down the machine the output choke and the other on the power board before the trouble damages internal machine compo- IGBT heat sink.

  • Page 36: Insulated Gate Bipolar Transistor (Igbt) Operation

    THEORY OF OPERATION INSULATED GATE BIPOLAR TRANSISTOR (IGBT) OPERATION An IGBT is a type of transistor. IGBTs are semicon- Drawing B shows the IGBT in an active mode. When ductors well suited for high frequency switching and the gate signal, a positive DC voltage relative to the high current applications.

  • Page 37: Pulse Width Modulation (Pwm

    THEORY OF OPERATION PULSE WIDTH MODULATION The positive portion of the signal represents one IGBT group conducting for 1 microsecond. The negative The term PULSE WIDTH MODULATION describes portion is the other IGBT group . The dwell time (off how much time is devoted to conduction in the posi- time) is 48 microseconds (both IGBT groups off).
  • Page 38 E-10 E-10 NOTES...
  • Page 39 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 PRO-CUT 55...

  • Page 40: Troubleshooting And Repair

    HOW TO USE TROUBLESHOOTING GUIDE 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 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.
  • Page 41 • If you return a PC Board to The Lincoln Electric Sometimes machine failures appear to be due to PC Company for credit, it must be in the static-shielding board failures.

  • Page 42: Troubleshooting Guide

    CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353. PRO-CUT 55...
  • Page 43 CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353. PRO-CUT 55...
  • Page 44 CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353. PRO-CUT 55...
  • Page 45 CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353. PRO-CUT 55...
  • Page 46 CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353. PRO-CUT 55...
  • Page 47 CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353. PRO-CUT 55...

  • Page 48: Input Filter Capacitor Discharge Procedure

    INPUT FILTER CAPACITOR DISCHARGE PROCEDURE WARNING Service and repair should be performed by only Lincoln Electric factory trained person- nel. Unauthorized repairs performed on this equipment may result in danger to the tech- nician 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.
  • Page 49 Input Power Board. FIGURE F.1 – LOCATION OF INPUT FILTER CAPACITOR TERMINALS INPUT UPPER POWER CAPACITOR TERMINALS BOARD LOWER CAPACITOR TERMINALS POWER RESISTOR INSULATED RIGHT SIDE OF MACHINE PLIERS INSULATED GLOVES PRO-CUT 55...

  • Page 50: Input Rectifier Test

    INPUT RECTIFIER TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained person- nel. Unauthorized repairs performed on this equipment may result in danger to the tech- nician 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.
  • Page 51 Discharge Procedure detailed earlier in tests detailed in Table F.1. See the Wiring this section. Diagram. 3. Locate the input rectifier (D1) and lead loca- tions. See Figure F.2. FIGURE F.2 – INPUT RECTIFIER AND LEADS #207 #207A #209 PRO-CUT 55...
  • Page 52 Primary Power Board 8. If the input rectifier is faulty, see the Input Resistance Test. Also check for leaky Rectifier Bridge Removal & Replacement or faulty filter capacitors. procedure. See the Wiring Diagram and Figure F.2. PRO-CUT 55...

  • Page 53: Primary Power Board Resistance Test And Capacitor Voltage Test

    CAPACITOR VOLTAGE 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 elec-...
  • Page 54 2. Perform the Input Filter Capacitor Discharge Procedure detailed earlier in 5. Use the analog ohmmeter to perform the this section. test outlined in Table F.2. 3. Locate the primary power board and asso- ciated lead locations. See Figure F.3. PRO-CUT 55...
  • Page 55 Removal Replacement may be faulty. These circuits are NOT readi- Procedure. ly tested or serviceable. NOTE: Complete power board and filter 8. Reconnect leads #201, #204, #205 and #208 capacitor replacement is recom- to their appropriate terminals. mended. PRO-CUT 55...
  • Page 56 PRIMARY POWER BOARD RESISTANCE TEST AND CAPACITOR VOLTAGE TEST (continued) CAPACITOR VOLTAGE TEST 4. The following tests will be performed with the input power applied to the Pro-Cut 55. This test will help the technician to determine if BE CAREFUL. ALWAYS REMOVE THE...
  • Page 57 TERMINALS 460VAC 325VDC 440VAC 311VDC 415VAC 293VDC 380VAC 269VDC 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. PRO-CUT 55...

  • Page 58: Output Power Board Resistance Test

    OUTPUT POWER BOARD RESISTANCE 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 elec-...
  • Page 59 G3326 - [ ] PRO-CUT 55 OUTPIUT (B12) Test Point TEST PROCEDURE 1. Remove input power to the Pro-Cut 55 4. Remove leads X4, X2, B21, X20, X40 and machine. plugs J33 and J32 from the output power board. See Figure F.4.
  • Page 60 F-22 F-22 TROUBLESHOOTING & REPAIR OUTPUT POWER BOARD RESISTANCE TEST (continued) TABLE F.4 - OUTPUT POWER BOARD RESISTANCE CIRCUIT OR TEST POINTS COMPONENT(S) EXPECTED RESISTANCE BEING TESTED +Probe J33-Pin4 Diode A1 Less than 100 ohms –Probe Terminal B11 associated trace +Probe Terminal B11 Diode A1 Greater than...

  • Page 61: Torch Continuity And Solenoid Test

    TORCH CONTINUITY AND SOLENOID 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 elec-...
  • Page 62 FIGURE F.5 - TORCH CONNECTOR - MACHINE END TEST PROCEDURE 3. Using the ohmmeter, check the torch resis- tances per Table F.5. 1. Remove input power to the Pro-Cut 55 NOTE: Take the “Pin” test point measurements machine. at the machine end of the torch assem- 2.

  • Page 63: Air/Gas Solenoid Test

    AIR/GAS SOLENOID 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 elec-...
  • Page 64 7. Install plug J31 back into the output power or very low resistance) of leads #366 and board. #361 between the solenoid and plug J31. FIGURE F.7 – PLUG J31 LOCATION (B11) G3326 - [ ] PRO-CUT 55 OUTPIUT (B12) Test Point PRO-CUT 55...

  • Page 65: T2 Auxiliary Transformer Test

    (T2) AUXILIARY TRANSFORMER 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 elec-...
  • Page 66 PLUG J22 T2 AUXILIARY TRANSFORMER PROCEDURE 1. Remove main input power to the Pro-Cut 55 5. Carefully apply the 230 VAC isolated supply machine. to leads H1 (1J22) and H3 (2J22) of the aux- iliary transformer. These leads are located in 2.
  • Page 67 9. If the auxiliary transformer tests good but it auxiliary transformer is good. does not function when connected to the Pro-Cut 55, check the harness wiring to the 8. If any of the voltages are missing or very low auxiliary transformer.

  • Page 68: Trigger Circuit Test

    TRIGGER CIRCUIT 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 elec-...
  • Page 69 PROCEDURE 7. If the correct voltage is present in Step 6, carefully check for the presence of approxi- 1. Remove input power to the Pro-Cut 55 mately 15 VDC from plug J32 pin-3 machine. (lead#344) (positive) to plug J32 pin-14 (lead#312) (negative).
  • Page 70 J32 pin-14 (lead#312) (nega- tive). 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 55. 10. Perform Input Filter Capacitor Discharge Procedure.
  • Page 71 F-33 F-33 TROUBLESHOOTING & REPAIR TRIGGER CIRCUIT TEST (continued) FIGURE F.10 - OUTPUT BOARD TRIGGER CIRCUIT TEST POINTS AND LEDS G3326 PRO-CUT 55 OUTPUT LED3 LED5 LEAD#2 LEAD#4 LEAD#312 LEAD#344 LED1 LED4 LED2 PRO-CUT 55 OUTPUT BOARD LED DEFINITIONS LED4: (Green) This light indicates that the trig-...
  • Page 72 F-34 F-34 TROUBLESHOOTING & REPAIR TRIGGER CIRCUIT TEST (continued) FIGURE F.11 - CONTROL BOARD LEDs PRO-CUT 55 CONTROL G3328 LED2 LED1 LED3 CONTROL BOARD LED DEFINITIONS LED1: (Red) This light indicates that 18 VAC is being supplied to the control board from the auxiliary transformer.

  • Page 73: Low Voltage Circuit Test

    LOW VOLTAGE CIRCUIT 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 elec-...
  • Page 74 #219 18VAC 10J40 BLUE PROCEDURE 1. Remove input power to the Pro-Cut 55 5. Check for the presence of 17 VDC on the out- machine. put board. 2. Using the 5/16" nutdriver remove the case a. LED2 should be lit when 17 VDC is present.
  • Page 75 F-37 F-37 TROUBLESHOOTING & REPAIR 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.
  • Page 76 F-38 F-38 TROUBLESHOOTING & REPAIR LOW VOLTAGE CIRCUIT TEST (continued) FIGURE F.13 – OUTBOARD LOW VOLTAGE CIRCUIT TEST POINTS AND LEDs G3326 PRO-CUT 55 OUTPUT LED3 LED5 PIN-6 LED1 LED4 LED2 PRO-CUT 55 OUTPUT BOARD LED DEFINITIONS LED4: (Green) This light indicates that the trig-...
  • Page 77 F-39 F-39 TROUBLESHOOTING & REPAIR LOW VOLTAGE CIRCUIT TEST (continued) FIGURE F.14 – CONTROL BOARD LEDs PRO-CUT 55 CONTROL G3328 LED2 LED1 LED3 CONTROL BOARD LED DEFINITIONS LED2: (Red) This light indicates that the +5.5 LED1: (Red) This light indicates that 18 VAC is VDC is present.

  • Page 78: Control Board Removal And Replacement

    CONTROL BOARD REMOVAL AND REPLACEMENT 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 elec-...
  • Page 79 CONTROL BOARD REMOVAL AND REPLACEMENT (continued) FIGURE F.16 - CASE FRONT SCREW REMOVAL 4 SCREWS PROCEDURE 1. Remove input power to the Pro-Cut 55 3. Using the 5/16” nut driver, remove the four machine. screws holding the front assembly to the top and base of the machine.
  • Page 80 F-42 F-42 TROUBLESHOOTING & REPAIR CONTROL BOARD REMOVAL AND REPLACEMENT (continued) 5. Locate the control board and the five molex 6. Carefully remove the five molex type plugs by type plugs connected to it. See Figure F.17. depressing the locking tabs and gently extracting the plugs from the P.C.

  • Page 81: Display Board Removal And Replacement

    DISPLAY BOARD REMOVAL AND REPLACEMENT 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 elec-...
  • Page 82 DISPLAY BOARD REMOVAL & REPLACEMENT (continued) FIGURE F.19 - CASE FRONT SCREW REMOVAL 4 SCREWS PROCEDURE 1. Remove the input power to the Pro-Cut 55 4. Carefully slide (do not force) the front away machine. from the rest of the machine about one inch.
  • Page 83 11. Inspect, clear and secure all leads in prepa- ration for the case wraparound reassembly. 7. Depress the locking tab and remove the plug 12. Using the 5/16” nut driver, install the case connector from the display board. wraparound. PRO-CUT 55...

  • Page 84: Output Power Board Removal And Replacement

    OUTPUT POWER BOARD REMOVAL AND REPLACEMENT 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 elec-...
  • Page 85 OUTPUT POWER BOARD REMOVAL & REPLACEMENT (continued) FIGURE F.21 – OUTPUT POWER BOARD REMOVAL OUTPUT POWER BOARD PROCEDURE 1. Remove input power to the Pro-Cut 55 3. Locate the output power P.C. board and machine. associated lead and plug connections. See Figures F.21 and F.22.
  • Page 86 TROUBLESHOOTING & REPAIR OUTPUT POWER BOARD REMOVAL & REPLACEMENT (continued) FIGURE F.22 – OUTPUT BOARD LEAD LOCATIONS G3326 - [ ] PRO-CUT 55 OUTPIUT 4. Using the 7/16” wrench, remove leads X4, X2 9. Carefully remove the output power board and B21 from the output power board.
  • Page 87 F-49 F-49 TROUBLESHOOTING & REPAIR REPLACEMENT PROCEDURE 1. Apply a thin coating of Penetrox A-13 Electrical Joint Compound to the mating sur- faces of the output power board and the heat sink. Make sure the surfaces are clean. Do not allow the compound to get into the threaded holes or on the screw threads.

  • Page 88: Primary Power Board And Filter Capacitor Removal And Replacement

    REMOVAL AND REPLACEMENT 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 elec-...
  • Page 89 PRIMARY POWER BOARD WITH INPUT FILTER CAPACITORS REMOVAL PROCEDURE 1. Remove input power from the Pro-Cut 55 4. Label the leads for reassembly. machine. 5. Remove Plug J10. 2. Remove the case wraparound and perform 6. Using the 7/16” wrench, remove leads 201,...
  • Page 90 F-52 F-52 TROUBLESHOOTING & REPAIR PRIMARY POWER BOARD AND FILTER CAPACITOR REMOVAL AND REPLACEMENT (continued) FIGURE F.24 – POWER BOARD HEATSINK AND CAPACITOR REMOVAL CAPACITOR CLAMP PRIMARY POWER P.C. BOARD 7/16" CAPACITOR BOLT (4) 3/8" MOUNTING INSULATOR (2) SOCKET HEAD MOUNTING SCREW (4) SCREW (2)
  • Page 91 F-53 F-53 TROUBLESHOOTING & REPAIR PRIMARY POWER BOARD AND FILTER CAPACITOR REMOVAL AND REPLACEMENT (continued) CAPACITOR REMOVAL 1. Using the 3/8” wrench, remove the four 4. Assemble the four socket head screws and screws holding the heat sink assembly to the pre-torque them to 25 inch-pounds.

  • Page 92: Input Rectifier Bridge Removal And Replacement

    INPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT 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 elec-...
  • Page 93 TROUBLESHOOTING & REPAIR INPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued) PROCEDURE 5. With the phillips head screw driver, remove the lead terminals connected to the rectifier 1. Remove input power to the Pro-Cut 55. terminals. 2. Perform Input Filter Capacitor 6.
  • Page 94 F-56 F-56 TROUBLESHOOTING & REPAIR 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.

  • Page 95: Retest After Repair

    INPUT IDLE AMPS AND WATTS Input Volts/Hertz Idle Amps Idle Watts 230/60 0.42 Output Current Range 25 - 55 Amps Maximum Open Circuit Voltage 335 Volts PRO-CUT 55...
  • Page 96 F-58 F-58 NOTES...
  • Page 97 ELECTRICAL DIAGRAMS TABLE OF CONTENTS ELECTRICAL DIAGRAMS SECTION Electrical Diagrams Section ..................Section G Wiring Diagram (208V, 230V, 460V) (L10634) ................G-2 Plasma Output Board Schematic (L10722) .................G-3 Power P.C. Board Schematic (L10616) ..................G-4 Display P.C. Board Assembly (L10721-1)..................G-5 Display Board (M18920) ......................G-6 Control Schematic (G3327) ......................G-7 Control P.C.

  • Page 98: Wiring Diagram (208V, 230V, 460V) (L10634

    ELECTRICAL DIAGRAMS Wiring Diagram (208V, 230V, 460V) (L10634) 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. L10634 8-7-98A...

  • Page 99: Plasma Output Board Schematic (L10722

    NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result PRO CUT 55 in danger to the Machine Operator or Technician.

  • Page 100: Power P.c. Board Schematic (L10616

    NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not 5-29-98H available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result PRO CUT 55...

  • Page 101: Display P.c. Board Assembly (L10721-1

    Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.

  • Page 102: Display Board (M18920

    Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.

  • Page 103: Control Schematic (G3327

    PRO CUT 55 available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.

  • Page 104: Control P.c. Board Assembly (G3328-1

    PRO CUT 55 available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.

  • Page 105: Control P.c. Board Assembly (G3328-2

    PRO CUT 55 available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.

  • Page 106: Output P.c. Board Assembly (G3326-1

    Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.

  • Page 107: Output P.c. Board Assembly (G3326-2

    Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.

  • Page 108: Power P.c. Board Assembly (G3172-1

    PRO CUT 55 available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.

  • Page 109: Power P.c. Board Assembly (G3172-2

    PRO CUT 55 available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.

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