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Lincoln Electric SVM104-A manual

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Table of contents for the manual

  • Page 1

    P P R R O O - - C C U U T T 6 6 0 0 ( ( S S i i n n g g l l e e P P h h a a s s e e ) ) SER VICE MANU AL F or use with machines having Code Numbers: 9819, 10096, 10112 10118, 10217, 10218 10393, 10394 SVM104-A March, 1999 Safety Depends on Y ou Lincoln arc welding and cutting equipment is designed and built with saf ety in mind. How e v er , y our [...]

  • Page 2

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRIC SHOCK can kill. 1.a. The electrode and work (or ground) circuits are electrically “hot” when the welder or cutter is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry , hole-free gloves to insulate hands. 1.b. Insulate[...]

  • Page 3

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FOR ELECTRICALL Y powered equipment. 6.a. T urn off input power using the disconnect switch at the fuse box before working on the equipment. 6.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer ’s recomm[...]

  • Page 4

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PRO-CUT 60 ELECTRIC AND MAGNETIC FIELDS may be dangerous 8.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding or cutting current creates EMF fields around welding or cutting cables and welding machines 8.b.[...]

  • Page 5

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 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 suiv- antes: Sûreté Pour Soudage A L?[...]

  • Page 6

    PRO-CUT 60 MASTER T ABLE OF CONTENTS FOR ALL SECTIONS Page Safety ................................................................................................................................iv Installation ..........................................................................................................Section A T echnical Specification[...]

  • Page 7

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Page Installation ............................................................................................................. Section A T echnical Specifications ............................................................................................... A-1 Sa[...]

  • Page 8

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Weight Including Machine T orch Cable (Length) (25ft/7.6m) (50ft/15.2m) 322 lbs. 329 lbs. 146 kg. 149 kg. INPUT - SINGLE PHASE / 60 HERTZ ONL Y RA TED OUTPUT OUTPUT RECOMMEND INP[...]

  • Page 9

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INST ALLA TION PRO-CUT 60 A-2 Read entire Installation Section before installing the PRO-CUT 60. SAFETY PRECAUTIONS ELECTRIC SHOCK CAN KILL. • Only qualified personnel should i[...]

  • Page 10

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INST ALLA TION PRO-CUT 60 A-3 3. Connect the work terminal to a ground within ten feet of the machine. a. Use grounding cable that is the same size as, or larger than, the work c[...]

  • Page 11

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FUSE AND WIRE SIZES Protect the input circuit with the super lag fuses or delay type circuit breakers listed on the Specifications page of this manual for the machine being used.[...]

  • Page 12

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INST ALLA TION PRO-CUT 60 A-5 AIR INPUT CONNECTIONS Supply the PRO-CUT 60 with clean compressed air or nitrogen. • Supply pressure must be between 70 psi and 120 psi (482 kPa a[...]

  • Page 13

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC RECONNECT PROCEDURE Multiple voltage machines are shipped connected to the highest input voltage listed on the machine's rating plate. Before installing the machine, check t[...]

  • Page 14

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INST ALLA TION PRO-CUT 60 A-7 OUTPUT CONNECTIONS T o avoid receiving a high frequency shock, keep the torch and cables in good condition. __________________ The standard PRO-CUT [...]

  • Page 15

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Page Operation ............................................................................................................... Section B Safety Precautions ...................................................................................................... B-1 Gen[...]

  • Page 16

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet clothing. • Insulate yourself from work and ground. • Always wear dry insulati[...]

  • Page 17

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OPERA TION PRO-CUT 60 B-2 GENERAL DESCRIPTION The PRO-CUT 60 is a constant current, single range, continuous control plasma cutting system. The microprocessor-based PRO-CUT 60 is[...]

  • Page 18

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC • W orks with pure nitrogen for cutting non-ferrous metal. • Smart switching of pilot contactor so that it does not switch under load. • Low fan noise at idle. • Modular [...]

  • Page 19

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ➀ ➁ ➂ ➃ ➄ OPERA TING STEPS 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 th[...]

  • Page 20

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OPERA TION PRO-CUT 60 B-5 8. Pull the torch trigger to cut. - OUTPUT ON LED glows. If postflow has not timed out, the pilot arc lights immediately . If postflow air has timed out[...]

  • Page 21

    6. Use nozzle with the largest orifice that gives the best cut f or the w ork being done. This pro- duces the best work results and consumable lif e. As the size of the nozzle orifice increases, its current capability increases. Therefore , the nozzle used f or cutting or gouging wor k must be able to handle the current needed to giv e the best cut[...]

  • Page 22

    OPERA TION PR O-CUT 60 B-7 Cutting Expanded Metal 1. Cut e xpanded metal with OUTPUT CURRENT CONTROL set near the mid- r ange position using the same methods listed under Cutting Thin Gauge Metal. K eep the follo wing points in mind: a. Place a thin piece of scrap metal o ver the area to be cut and then cut through both to mak e cutting easier . b [...]

  • Page 23

    Gouging Metal 1. Set the OUTPUT CURRENT CONTROL to maximum. 2. Use the plasma torch with a S24114 Dr ag Cup assemb ly or a S24162 shield cup. 3. Br ing the torch slowly towards the w or k piece at a 30 0 angle , but do not pierce the work piece. Do not touch the nozzle to the work piece. See Figure B .3. a. Blow molten metal a wa y from the torch. [...]

  • Page 24

    NOTES B-9 PRO-CUT 60 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 25

    Page Accessories ............................................................................................................ Section C Accessories ....................................................................................................................C-1 T ABLE OF CONTENTS - ACCESSORIES SECTION - PRO-CUT 60 Section C Return to Master T[...]

  • Page 26

    OPTIONS/A CCESSORIES DRA G CUP ASSEMBL Y (S24114) The drag cup protects the torch b y prev enting the torch from touching the workpiece. SHIELD CUP ASSEMBL Y (S24162) This shields the torch tip and provides more visibil- ity to the workpiece than the drag cup . Note the shield cup does not pre vent the torch tip from touching the workpiece. T ORCH [...]

  • Page 27

    Page Maintenance ..................................................................................................... Section D Safety Precautions ...................................................................................................D-1 Capacitor Discharge Procedure .....................................................................[...]

  • Page 28

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Only qualified personnel should perform this mainte- nance. • T urn the input power OFF at the disconnect switch or fuse box bef[...]

  • Page 29

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC MAINTENANCE PROCEDURE NOTE: See Figure D.1. 1. Disconnect input power to the machine. 2. Remove the Left Case Side Assembly . 3. Locate the two capacitors shown Figure D.1 and D.[...]

  • Page 30

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC MAINTENANCE PRO-CUT 60 D-3 ROUTINE AND PERIODIC MAINTENANCE 1. Disconnect input power supply lines to the machine before performing periodic main- tenance, tightening, cleaning, [...]

  • Page 31

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC MAINTENANCE PRO-CUT 60 D-4 ➀ CASE FRONT ASSEMBL Y ➁ CASE BACK ASSEMBL Y ➂ INPUT BOX ASSEMBL Y ➃ CONTROL P ANEL ASSEMBL Y ➄ HIGH FREQUENCY BOARD ASSEMBL Y ➅ BASE ASSEM[...]

  • Page 32

    NOTES D-5 PRO-CUT 60 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 33

    FIGURE E.1 Block Logic Diagram Page Theory of Operation Section ...................................................................... Section E Power Supply Operation .............................................................................E-1 - E-4 Input Line V oltage and Main Transformer ......................................................[...]

  • Page 34

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INPUT LINE VOL T AGE AND MAIN TRANSFORMER The desired single-phase input power is connect- ed to the Pro-Cut 60 through a line switch located on the front panel of the machine. A[...]

  • Page 35

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC THEOR Y OF OPERA TION PRO-CUT 60 E-2 FIGURE E.3 - Output Rectification, Control and Feedback OUTPUT RECTIFICA TION, CONTROL AND FEEDBACK The AC output from the main transformer s[...]

  • Page 36

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PRO-CUT 60 HIGH VOL T AGE / HIGH FREQUENCY AND BY -P ASS CIRCUIT The control board passes the 1 15vac through the CR2 relay contacts to the primary of the high volt- age transfor[...]

  • Page 37

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC THEOR Y OF OPERA TION PRO-CUT 60 E-4 FIGURE E.6 - Pilot Lead Circuit FIGURE E.5 - Pilot Arc PILOT ARC The Pro-Cut 60 has a smooth, continuous pilot arc. The pilot arc is a means [...]

  • Page 38

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PRO-CUT 60 E-5 TRANSIST OR SWITCHING OPERA TION A transistor is a solid state device consisting of three layers of silicon crystal. These three layers form the emitter , collecto[...]

  • Page 39

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC THEOR Y OF OPERA TION PRO-CUT 60 E-6 PULSE WIDTH MODULA TION The term PULSE WIDTH MODULA TION is used to describe how much of a given time period is devoted to conduction(collect[...]

  • Page 40

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PRO-CUT 60 E-7 NOTES[...]

  • Page 41

    PRO-CUT 60 Section F T ABLE OF C O NTENTS - TROUBLESHOOTING & REP AIR SECTION - Page T roubleshooting & Repair Section .............................................................................Section F Safety Precautions..............................................................................................................F-1 How [...]

  • Page 42

    TROUBLESHOOTING & REP AIR PRO-CUT 60 F-1 HOW T O USE TROUBLESHOOTING GUIDE Service and Repair should only be performed by Lincoln Electric Factory T rained 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 avo[...]

  • Page 43

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING PRO-CUT 60 F-2 CAUTION: Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections. T[...]

  • Page 44

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR PRO-CUT 60 F-3 PROBLEMS (SYMPTOMS) Major Physical or Electrical Damage is Evident No LEDs light when the ON/OFF Power Switch is turned "ON"[...]

  • Page 45

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR PRO-CUT 60 F-4 Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) No LEDs light when the [...]

  • Page 46

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR PRO-CUT 60 F-5 PROBLEMS (SYMPTOMS) The air begins to flow , the "OUTPUT ON" LED lights for a short time, but no pilot arc is established. [...]

  • Page 47

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR PRO-CUT 60 F-6 Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) The air begins to flow [...]

  • Page 48

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR PRO-CUT 60 F-7 PROBLEMS (SYMPTOMS) The "THERMAL" LED is lit. The "MALFUNCTION" or "F AUL T" LED is blinking. The machi[...]

  • Page 49

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR PRO-CUT 60 F-8 Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) The "OUTPUT ON&quo[...]

  • Page 50

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR PRO-CUT 60 F-9 PROBLEMS (SYMPTOMS) Airflow does not shut off. The "OUTPUT ON" and "AIR PRESSURE" LED's blink in alternating[...]

  • Page 51

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR PRO-CUT 60 F-10 Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) The "MACHINE ON&q[...]

  • Page 52

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR PRO-CUT 60 F-1 1 PROBLEMS (SYMPTOMS) The arc starts but sputters badly . (If cutting expanded metal, condition may be nor- mal, see operation sectio[...]

  • Page 53

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC G2015 PRO•CUT 60 SINGLE PHASE J6 J7 J10 8J5 7J5 6J5 5J5 4J5 6J10 J4 J2 J8 J5 L7941 POWER BOARD J22 1J22 2J22 1J20 4J22 2J20 3J22 4J20 #40 NEG C C LEADS NEG LEAD H1 LEAD H1 H2 H[...]

  • Page 54

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CAP ACITOR DISCHARGE PROCEDURE Failure to follow this capacitor discharge procedure can result in electric shock. PROCEDURE DESCRIPTION This procedure must be performed before an[...]

  • Page 55

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR PRO-CUT 60 F-14 CAP ACITOR DISCHARGE PROCEDURE PROCEDURE NOTE: See Figure F .19. 1. Disconnect input power to the machine. 2. Remove the Left Case S[...]

  • Page 56

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ORCH, TORCH CABLE ASSEMBL Y , INTERNAL TRIGGER, AND SAFETY CIRCUIT TEST TEST DESCRIPTION This test will identify any problems or faults in the torch, torch cable assembly , and[...]

  • Page 57

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR PRO-CUT 60 F-16 T ORCH, TORCH CABLE ASSEMBL Y , INTERNAL TRIGGER, AND SAFETY CIRCUIT TEST TORCH AND CABLE RESIST ANCE TEST PROCEDURE 1. T urn PRO-CU[...]

  • Page 58

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC d. Disconnect the trigger lead 4-pin connector by unscrewing it. e. Disconnect the electrode lead using a 9/16” open-end wrench to remove the brass adaptor fit- ting attached t[...]

  • Page 59

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR PRO-CUT 60 F-18 INTERNAL TRIGGER AND SAFETY CIRCUIT TEST PROCEDURE 1. T urn the PRO-CUT 60 ON/OFF Power Switch to OFF . 2. Disconnect input power su[...]

  • Page 60

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 8. Disconnect Plug J5 from its header on the Control Board. 9. T est for zero ohms (continuity) from the following test points on Plug J5 header to the 4-pin leads on the bulkhea[...]

  • Page 61

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC G2015 PRO•CUT 60 SINGLE PHASE J6 J7 J10 J4 J2 J8 2 4 1 3 8J5 3J5 REMOVE J5 PLUG 6J5 4J5 J5 4- PIN RECEPT ACLE IN BULKHEAD TROUBLESHOOTING & REP AIR PRO-CUT 60 F-20 T ORCH, [...]

  • Page 62

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TEST DESCRIPTION This test will identify any problems or faults in the T ransistor Module. TROUBLESHOOTING & REP AIR PRO-CUT 60 F-21 TRANSIST OR MODULE TEST POWER PC BOARD FI[...]

  • Page 63

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC MA TERIALS NEEDED - Analog V olt/Ohmmeter (Multimeter) with RX10 or RX1000 scale. - PRO-CUT 60 Wiring Diagrams - Phillips Head Screwdriver TEST PROCEDURE 1. T urn ON/OFF Power Sw[...]

  • Page 64

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC L7941 POWER BOARD J22 1J22 2J22 1J20 4J22 2J20 3J22 4J20 #40 NEG C C LEADS NEG LEAD H1 LEAD H1 H2 H2 LEAD #40 LEADS J20 G1 G2 B 40 J21 1J21 MOUNTING SCREWS TROUBLESHOOTING & [...]

  • Page 65

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR PRO-CUT 60 F-24 MAIN TRANSFORMER TEST TEST DESCRIPTION This test will identify any problems or faults in the Main T ransformer ’s primary and seco[...]

  • Page 66

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR PRO-CUT 60 (12/95) F-25 MAIN TRANSFORMER TEST TEST PROCEDURE 1. Connect main input power supply to machine. NOTE: When performing T ests A and B a. [...]

  • Page 67

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR PRO-CUT 60 F-26 MAIN TRANSFORMER TEST CONTROL PC BOARD POWER PC BOARD CONTROL RELA Y (CR2) FIGURE F .10 Main T ransformer T est Components L1 METER [...]

  • Page 68

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR PRO-CUT 60 F-27 POWER BOARD TEST HIGH VOL T AGE/HIGH FREQUENCY CAN DAMAGE TEST EQUIPMENT TEST DESCRIPTION This test will identify any problems or fa[...]

  • Page 69

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC L7941 POWER BOARD J22 1J22 2J22 1J20 4J22 2J20 3J22 4J20 #40 NEG C C LEADS NEG LEAD H1 LEAD H1 H2 H2 LEAD #40 LEADS J20 G1 G2 B 40 J21 1J21 MOUNTING SCREWS TEST PROCEDURE 1 . Con[...]

  • Page 70

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR PRO-CUT 60 F-29 POWER BOARD TEST T est B: T est for 7 VDC signal between Power Board and Control Board NOTE: This test requires that the torch trigg[...]

  • Page 71

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T est D: T est for 0.2 VDC to 0.3 VDC Gate Drive V oltages to the SCR Module. NOTE: This test requires that the torch trigger be pulled to activate the circuit. Be sure to use an[...]

  • Page 72

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR PRO-CUT 60 F-31 HIGH VOL T AGE TRANSFORMER AND CIRCUIT TEST HIGH VOL T AGE/HIGH FREQUENCY CAN DAMAGE TEST EQUIPMENT TEST DESCRIPTION This test will [...]

  • Page 73

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR PRO-CUT 60 F-32 HIGH VOL T AGE TRANSFORMER AND CIRCUIT TEST TEST PROCEDURE NOTE: This test can be performed best with alligator clips used with the [...]

  • Page 74

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T est B: T est Resistance of High V oltage T ransformer Primary 1. Disconnect input power to machine. 2. T urn ON/OFF Power Switch to OFF . 3. Perform the CAP ACITOR DISCHARGE PR[...]

  • Page 75

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR PRO-CUT 60 F-34 ON/OFF POWER SWITCH REMOV AL REMOV AL/REPLACEMENT DESCRIPTION This procedure will assist you in removing or replacing the ON/OFF Pow[...]

  • Page 76

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ON/OFF POWER SWITCH REMOV AL (LA TER CODES MA Y HA VE TOGGLE SWITCH) TROUBLESHOOTING & REP AIR PRO-CUT 60 F-35 REMOV AL/REPLACEMENT PROCEDURE 1. Disconnect input power to the[...]

  • Page 77

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR PRO-CUT 60 F-36 CONTROL BOARD REMOV AL Printed Circuit Boards can be damaged by static electricity . REMOV AL/REPLACEMENT DESCRIPTION This procedure[...]

  • Page 78

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR PRO-CUT 60 F-37 CONTROL BOARD REMOV AL REMOV AL/REPLACEMENT PROCEDURE 1. Disconnect input power to the machine. 2. Remove the Left Case Side assembl[...]

  • Page 79

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR PRO-CUT 60 F-38 POWER BOARD REMOV AL Printed Circuit Boards can be damaged by static electricity . REMOV AL/REPLACEMENT DESCRIPTION This procedure w[...]

  • Page 80

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC L7941 POWER BOARD J22 1J22 2J22 1J20 4J22 2J20 3J22 4J20 #40 NEG C C LEADS NEG LEAD H1 LEAD H1 H2 H2 LEAD #40 LEADS J20 G1 G2 B 40 J21 1J21 MOUNTING SCREWS TROUBLESHOOTING & [...]

  • Page 81

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 8. Remove the four mounting Phillips head screws holding the Power Board to the SCR module. 9. Remove the two nylon nuts from the studs on which the Power Board is mounted with a[...]

  • Page 82

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR PRO-CUT 60 F-41 TRANSIST OR MODULE REMOV AL Printed Circuit Boards can be damaged by static electricity . REMOV AL/REPLACEMENT DESCRIPTION This proc[...]

  • Page 83

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR PRO-CUT 60 F-42 TRANSIST OR MODULE REMOV AL REMOV AL/REPLACEMENT PROCEDURE NOTE: It is recommended that when the T ransistor Module is replaced, the[...]

  • Page 84

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR PRO-CUT 60 F-43 SCR MODULE REMOV AL Printed Circuit Boards can be damaged by static electricity . REMOV AL/REPLACEMENT DESCRIPTION This procedure wi[...]

  • Page 85

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR PRO-CUT 60 F-44 SCR MODULE REMOV AL REMOV AL/REPLACEMENT PROCEDURE NOTE: See Figure F .16. 1. Disconnect input power to the machine. 2. Remove the L[...]

  • Page 86

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR PRO-CUT 60 F-45 SCR MODULE REMOV AL b. Rinse the heat sink surface with alcohol or acetone. c. Apply a .002” to .005” coat of joint compound eve[...]

  • Page 87

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC REMOV AL/REPLACEMENT DESCRIPTION This procedure will assist you in removing or replacing the fan blade and fan motor in case of a faulty motor or broken fan blade. MA TERIALS NEE[...]

  • Page 88

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC REMOV AL/REPLACEMENT PROCEDURE NOTE: See Figure F .17. 1. Disconnect input power to the machine. 2. Perform the CAP ACITOR DISCHARGE PROCEDURE. 3. Disconnect the air line to the [...]

  • Page 89

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 9. Pull the rubber air line hose into the machine out of the rubber grommet. Be sure to keep the Case Back Assembly support- ed. Allow it to lean out away from the machine at abo[...]

  • Page 90

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR PRO-CUT 60 F-49 TORCH HEAD REMOV AL/REPLACEMENT REMOV AL/REPLACEMENT DESCRIPTION This procedure will assist you in the replacing torch head componen[...]

  • Page 91

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR PRO-CUT 60 F-50 TORCH HEAD REMOV AL/REPLACEMENT REMOV AL/REPLACEMENT PROCEDURE NOTE: See Figure F .18. 1. Disconnect input power to the machine. 2. [...]

  • Page 92

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR PRO-CUT 60 F-51 TORCH HEAD REMOV AL/REPLACEMENT d. Disconnect the trigger lead 4-pin connector by unscrewing it. e. Disconnect the electrode lead us[...]

  • Page 93

    INPUT IDLE AMPS MAXIMUM ACCEPT ABLE OUTPUT VOL T AGE - A T MINIMUM OUTPUT SETTING MINIMUM ACCEPT ABLE OUTPUT VOL T AGE - A T MAXIMUM OUTPUT SETTINGS RECOMMENDED METERS FOR MACHINE OUTPUT TESTS VOL TMETER: Analog type meter TROUBLESHOOTING & REP AIR PRO-CUT 60 F-52 RETEST AFTER REP AIR Should a machine under test be rejected for any reason requi[...]

  • Page 94

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-53 NOTES PRO-CUT 60[...]

  • Page 95

    Page Electrical Diagrams ...................................................................................... Section G Status Board Schematic (M15601) ..........................................................................G-2 Bypass Board Schematic (M15603) ........................................................................G-3 Bypass Boa[...]

  • Page 96

    ELECTRICAL DIAGRAMS PRO-CUT 60 G-2 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ST A TUS BOARD SCHEMA TIC DIAGRAM 1-26-90 2J9 LED1 LED2 LED3 6J9 5J9 3J9 R1 470 1J9 LED6 LED5 LED4 7J9 8J9 ELECTRICAL SYMBOLS PER E1537 S18648 [...]

  • Page 97

    ELECTRICAL DIAGRAMS PRO-CUT 60 G-3 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC G-3 BYP ASS BOARD SCHEMA TIC DIAGRAM (M15603) C2 C7 C8 C1 C3 C5 C6 C10 C4 C9 TP1 .05 600 .05 600 .05 600 .05 600 .05 1000 .05 1000 .05 1000 .05[...]

  • Page 98

    ELECTRICAL DIAGRAMS PRO-CUT 60 G-4 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC BYP ASS BOARD SCHEMA TIC DIAGRAM (M17322) NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubles[...]

  • Page 99

    NOTES PRO-CUT 60 G-5 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 100

    ELECTRICAL DIAGRAMS PRO-CUT 60 G-6 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CONTROL BOARD Y1 PRO-CUT 60 SINGLE PHASE G2015 NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level tro[...]

  • Page 101

    ELECTRICAL DIAGRAMS PRO-CUT 60 G-7 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CONTROL BOARD X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . .IC,NMOS,MCU,68705R3CS X5 . . . . . . . . . . . . . . .IC-CMOS,GA TE,NAN[...]

  • Page 102

    ELECTRICAL DIAGRAMS PRO-CUT 60 G-8 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER BOARD L7941-3 POWER BOARD NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. P[...]

  • Page 103

    ELECTRICAL DIAGRAMS PRO-CUT 60 G-9 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER BOARD Item . . . . . . . . . . . . . . . . . . . .Identification Q4 . . . . . . . . . . . . . . . . . . . . .TRANSIST OR HEA T SINK ASBL [...]

  • Page 104

    ELECTRICAL DIAGRAMS PRO-CUT 60 G-10 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ST A TUS PC BOARD M15601 PROCUT 60 ST A TUS LED1 LED2 LED3 LED4 LED5 LED6 R1 CONNECT OR ON BOARD BACK NOTE: Lincoln Electric assumes no respon[...]

  • Page 105

    ELECTRICAL DIAGRAMS PRO-CUT 60 G-11 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ST A TUS PC BOARD M15601 Item . . . . . . . . . . . . . . .Identification R1 . . . . . . . . . . . . . . . . .RESISTOR-MF , 1/2W , 470, 2% LED[...]

  • Page 106

    ELECTRICAL DIAGRAMS PRO-CUT 60 G-12 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC BYP ASS PC BOARD (M15603)   M15603 BYPASS C10 C6 C9 C1 C5 C4 TP2 TP1 C2 C3 C7 C8 POS 71 NOTE: Lincoln Electric assumes no responsibility[...]

  • Page 107

    ELECTRICAL DIAGRAMS PRO-CUT 60 G-13 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC BYP ASS PC BOARD (M15603) Item . . . . . . . . . . . . . . .Identification C1,C6,C8,C10 . . . . . . . .0.047uF , 1000V , 10% C2,C4,C7,C9 . . .[...]

  • Page 108

    ELECTRICAL DIAGRAMS PRO-CUT 60 G-14 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC BYP ASS PC BOARD (M17322) PRO-CUT 60 SINGLE PHASE BYPASS M17322 NOTE: Lincoln Electric assumes no responsibility for liablilities resulting fr[...]

  • Page 109

    ELECTRICAL DIAGRAMS PRO-CUT 60 G-15 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC BYP ASS PC BOARD (M17322) Item . . . . . . . . . . . . . . . . . . . . . .Identification B71,B72,B389,BGND1,BPOS2 . .1/4" T AB TERMINAL T[...]

  • Page 110

    ELECTRICAL DIAGRAMS G-16 PRO-CUT 60 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. WIRING DIAGRAM FOR CODES 101 12, 101 18 NOTE: This diagram is for reference only . It may not be accura[...]

  • Page 111

    ELECTRICAL DIAGRAMS G-17 PRO-CUT 60 WIRING DIAGRAM FOR CODES 9819, 10096 STATUS BOARD 1 2 3 4 5 6 8 7 J9 211 212 213 214 215 216 218 325 326 SAFETY RESET S3 2 L2 S1 TS1 TO PRIMARY COILS TO SUPPLY LINES TO GROUND PER NATIONAL ELECTRICAL CODE TO GROUND PER NATIONAL ELECTRICAL CODE TO PRIMARY COILS S1 TS1 TO SUPPLY LINES L2 2 OUTPUT CONTROL 1 3 2 CW R[...]

  • Page 112

    ELECTRICAL DIAGRAMS G-18 PRO-CUT 60 CONTROL BOARD SCHEMA TIC DRA WING (G2015) 2.21K R30 P8 J8 1 P8 J8 2 P8 J8 13 P8 J8 9 475 R154 2.21K R174 P2 J2 6 "THERMOSTAT" 1.00K R74 1.0 50V C18 P8 J8 8 600mA 40V Q15 10K R104 P8 J8 15 1W 5.1V DZ14 P8 J8 6 .33mH L7 1W 5.1V DZ15 100 R27 1.00K R72 475 R155 100 R31 475 R28 P2 J2 3 1.0 50V C17 +5 V +5 V [...]

  • Page 113

    ELECTRICAL DIAGRAMS G-19 PRO-CUT 60 POWER BOARD SCHEMA TIC DESIGN 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[...]

  • Page 114

    SVM ERR OR REPORTING FORM W e need to know if there are errors in our manuals . We also v alue any suggestions as to additional tests or procedures that would mak e this SVM a better tool for y ou. If you disco ver ne w or different “Prob lems or Symptoms” that are not cov ered in the three col- umn troubleshooting chart, please share this info[...]