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IM422-A
PRO - CUT 40 â„? October, 1995
PLASMA CUTTING POWER SOURCE - for Single Phase Input - Code Numbers 9628-1 & -2 only
Safety Depends on You
Lincoln plasma cutting equipment
is designed and built with safety in
mind. However, your overall safety
can be increased by proper instal-
lation ... 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.
OPERATOR’S MANUAL
World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors
Sales and Service through Subsidiaries and Distributors Worldwide
22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A. Tel. (216) 481-8100
WARNING PLASMA CUTTING or GOUGING 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 safety highlights. For additional safety information it is strongly recommended that you pur-
chase 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.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
ELECTRIC SHOCK can FUMES AND GASES
kill. can be dangerous.
1.a. The electrode and work (or ground) circuits 3.a. Plasma cutting or gouging may produce
are electrically “hot� when the power source fumes and gases hazardous to health.
is on. Do not touch these “hot� parts with Avoid breathing these fumes and
your bare skin or wet clothing. Wear dry, gases.When cutting or gouging, keep your
hole-free gloves to insulate hands. head out of the fumes. Use enough ventila-
tion and/or exhaust at the arc to keep fumes and gases
away from the breathing zone. When cutting or gouging
1.b. When the power source is operating voltages in excess of
on lead or cadmium plated steel and other metals or
250 volts are produced. This creates the potential for serious
coatings which produce highly toxic fumes keep expo-
electrical shock - potentially even fatal.
sure as low as possible and below Threshold Limit
Values (TLV) using local exhaust or mechanical ventila-
1.c. Insulate yourself from work and ground using dry insulation.
tion. In confined spaces or in some circumstances, out-
When cutting or gouging in damp locations, on metal frame-
doors, a respirator may be required. Additional precau-
work such as floors, gratings or scaffolds and when in posi-
tions are also required when welding on galvanized
tions such as sitting or lying, make certain the insulation is steel.
large enough to cover your full area of physical contact with
3.b. Do not use plasma arc cutting or gouging in locations near
work and ground.
chlorinated hydrocarbon vapors coming from degreasing,
1.d. Always be sure the work cable makes a good electrical con- cleaning or spraying operations. The heat and rays of the arc
can react with solvent vapors to form phosgene, a highly
nection with the metal being cut or gouged. The connection
toxic gas, and other irritating products.
should be as close as possible to the area being cut or
gouged. 3.c. Gases used for plasma cutting and gouging can displace air
and cause injury or death. Always use enough ventilation,
1.e. Ground the work or metal to be cut or gouged to a good elec-
especially in confined areas, to insure breathing air is safe.
trical (earth) ground.
3.d. Read and understand the manufacturer’s instructions for this
1.f. Maintain the plasma torch, cable and work clamp in good, equipment and the consumables to be used, including the
safe operating condition. Replace damaged insulation. material safety data sheet (MSDS) and follow your employ-
er’s safety practices.
1.g. Never dip the torch in water for cooling or plasma cut or
gouge in or under water.
CUTTING SPARKS can
1.h. When working above floor level, protect yourself from a fall
should you get a shock.
cause fire or explosion.
1.i. Operate the pilot arc with caution. The pilot arc is capable of
4.a..Remove fire hazards from the plasma cut-
burning the operator, others or even piercing safety clothing.
ting or gouging area. If this is not possible,
cover them to prevent the cutting or gouging
1.j. Also see Items 4c and 6.
sparks from starting a fire. Remember that
welding sparks and hot materials from plasma cutting or
gouging can easily go through small cracks and openings to
adjacent areas. Avoid cutting or gouging near hydraulic lines.
Have a fire extinguisher readily available.
4.b. Where compressed gases are to be used at the job site, spe-
cial precautions should be used to prevent hazardous situa-
tions. Refer to “Safety in Welding and Cutting� (ANSI
Standard Z49.1) and the operating information for the equip-
ARC RAYS can burn. ment being used.
2.a. Use safety glasses and a shield with the prop-
er filter and cover plates to protect your eyes 4.c. When not cutting or gouging, make certain no part of the elec-
from sparks and the rays of the arc when per- trode circuit is touching the work or ground. Accidental con-
forming or observing plasma arc cutting or tact can cause overheating and create a fire hazard.
gouging. Glasses,headshield and filter lens
should conform to ANSI Z87. I standards. 4.d. Do not cut or gouge tanks, drums or containers until the prop-
er steps have been taken to insure that such procedures will
2.b. Use suitable clothing including gloves made from durable not cause flammable or toxic vapors from substances inside.
flame-resistant material to protect your skin and that of your They can cause an explosion even though they have been
helpers from the arc rays. “cleaned.� For information purchase “Recommended Safe
Practices for the Preparation for Welding and Cutting of
2.c. Protect other nearby personnel with suitable non-flammable Containers and Piping That Have Held Hazardous
screening and/or warn them not to watch the arc nor expose Substances�, AWS F4.1 from the American Welding Society
themselves to the arc rays or to hot spatter or metal. (see address above).
4.e. Vent hollow castings or containers before heating, cutting or
gouging. They may explode.
4.f. Do nor fuel engine driven equipment near area where plasma
cutting or gouging.
�2�
Apr. �93
4.g. Sparks and spatter are thrown from the plasma arc. Wear
PLASMA ARC can injure.
safety glasses, ear protection and oil free protective garments
such as leather gloves, heavy shirt, cuffless trousers, high
shoes and a cap over your hair. Wear ear plugs when cutting
7.a. Keep your body away from nozzle and
or gouging out of position or in confined places. Always wear
plasma arc.
safety glasses with side shields when in a cutting or gouging
area.
7.b. Operate the pilot arc with caution. The pilot arc is capable of
4.h. Connect the work cable to the work as close to the cutting or
burning the operator, others or even piercing safety clothing.
gouging area as practical. Work cables connected to the build-
ing framework or other locations away from the cutting or
gouging area increase the possibility of the 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.
CYLINDER may explode
if damaged.
5.a. Use only compressed gas cylinders contain-
ing the correct 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 main-
ELECTRIC AND MAGNETIC FIELDS
tained in good condition.
may be dangerous
5.b. Always keep cylinders in an upright position securely
8.a. Electric current flowing through any con-
chained to an undercarriage or fixed support.
ductor causes localized Electric and
5.c. Cylinders should be located: Magnetic Fields (EMF). Cutting or gouging
� Away from areas where they may be struck or subjected to current creates EMF fields around torch
physical damage. cables and cutting machines.
� A safe distance from plasma cutting or gouging, arc weld-
ing operations and any other source of heat, sparks, 8.b. EMF fields may interfere with some pacemakers, so opera-
or flame. tors having a pacemaker should consult their physician
before cutting or gouging.
5.d. Never allow any part of the electrode, torch or any other
electrically “hot� parts to touch a cylinder.
8.c. Exposure to EMF fields during cutting or gouging may have
other health effects which are now not known.
5.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
8d. All operators should use the following procedures in order to
5.f. Valve protection caps should always be in place and hand minimize exposure to EMF fields from the cutting or gouging
tight except when the cylinder is in use or connected for circuit:
use.
8.d.1. Route the torch and work cables together - Secure
5.g. Read and follow the instructions on compressed gas cylin- them with tape when possible.
ders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in 8.d.2. Never coil the torch cable around your body.
Cylinders,â€available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202. 8.d.3. Do not place your body between the torch and
work cables. If the torch cable is on your right side,
FOR ELECTRICALLY the work cable should also be on your right side.
powered equipment. 8.d.4. Connect the work cable to the workpiece as close as
possible to the area being cut or gouged.
6.a. Turn off input power using the disconnect
switch at the fuse box before working on
8.d.5. Do not work next to cutting power source.
the equipment.
6.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s rec-
ommendations.
6.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
�3� Apr. �93
zones où l’on pique le laitier.
PRÉCAUTIONS DE SÛRETÉ
6. Eloigner les matériaux inflammables ou les recouvrir afin de
Pour votre propre protection lire et observer toutes les instructions
prévenir tout risque d’incendie dû aux étincelles.
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv-
7. Quand on ne soude pas, poser la pince à une endroit isolé de
antes:
la masse. Un court-circuit accidental peut provoquer un échauf-
fement et un risque d’incendie.
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
8. S’assurer que la masse est connectée le plus prés possible de
la zone de travail qu’il est pratique de le faire. Si on place la
a. Les circuits à l’électrode et à la piéce sont sous tension
masse sur la charpente de la construction ou d’autres endroits
quand la machine à souder est en marche. Eviter toujours
éloignés de la zone de travail, on augmente le risque de voir
tout contact entre les parties sous tension et la peau nue ou
passer le courant de soudage par les chaines de levage,
les vétements mouillés. Porter des gants secs et sans trous
câbles de grue, ou autres circuits. Cela peut provoquer des
pour isoler les mains.
risques d’incendie ou d’echauffement des chaines et des
b. Faire trés attention de bien s’isoler de la masse quand on
câbles jusqu’� ce qu’ils se rompent.
soude dans des endroits humides, ou sur un plancher met-
allique ou des grilles metalliques, principalement dans
9. Assurer une ventilation suffisante dans la zone de soudage.
les positions assis ou couché pour lesquelles une grande
Ceci est particuliérement important pour le soudage de tôles
partie du corps peut être en contact avec la masse.
galvanisées plombées, ou cadmiées ou tout autre métal qui
c. Maintenir le porte-électrode, la pince de masse, le câble de
produit des fumeés toxiques.
soudage et la machine à souder en bon et sûr état defonc-
tionnement.
10. Ne pas souder en présence de vapeurs de chlore provenant
d.Ne jamais plonger le porte-électrode dans l’eau pour le
d’opérations de dégraissage, nettoyage ou pistolage. La
refroidir.
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
e. Ne jamais toucher simultanément les parties sous tension
du solvant pour produire du phosgéne (gas fortement toxique)
des porte-électrodes connectés à deux machines à souder
ou autres produits irritants.
parce que la tension entre les deux pinces peut être le total
de la tension à vide des deux machines.
11. Pour obtenir de plus amples renseignements sur la sûreté, voir
f. Si on utilise la machine à souder comme une source de
le code “Code for safety in welding and cutting� CSA Standard
courant pour soudage semi-automatique, ces precautions
W 117.2-1974.
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
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
enrouler le câble-électrode autour de n’importe quelle partie du
corps.
PRÉCAUTIONS DE SÛRETÉ POUR
3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:
LES MACHINES À SOUDER À
a. Utiliser un bon masque avec un verre filtrant approprié ainsi
TRANSFORMATEUR ET À
qu’un verre blanc afin de se protéger les yeux du rayon-
nement de l’arc et des projections quand on soude ou
REDRESSEUR
quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la peau
1. Relier à la terre le chassis du poste conformement au code de
de soudeur et des aides contre le rayonnement de l‘arc.
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
c. Protéger l’autre personnel travaillant à proximité au
bonne mise à la terre.
soudage à l’aide d’écrans appropriés et non-inflammables.
2. Autant que possible, I’installation et l’entretien du poste seront
4. Des gouttes de laitier en fusion sont émises de l’arc de
effectués par un électricien qualifié.
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan-
3. Avant de faires des travaux à l’interieur de poste, la debrancher
talons sans revers, et chaussures montantes.
à l’interrupteur à la boite de fusibles.
5. Toujours porter des lunettes de sécurité dans la zone de
4. Garder tous les couvercles et dispositifs de sûreté à leur place.
soudage. Utiliser des lunettes avec écrans lateraux dans les
�4� Mar. �93
TABLE OF CONTENTS
Page
Safety Precautions .............................................................................................................2-4
Introductory Information .......................................................................................................6
Product Description..............................................................................................................7
Preheat Temperature for Plasma Cutting ............................................................................7
User Responsibility ..............................................................................................................7
Specifications.......................................................................................................................7
Installation ..........................................................................................................................8-1
Safety Precautions ........................................................................................................8
Location .........................................................................................................................8
High Frequency Interference Protection........................................................................8
Electrical Input Connection............................................................................................9
Electrical Installation for PRO-CUT 40....................................................................9
Capacitor Discharge Procedure ..............................................................................9
Input Voltage Setup ................................................................................................9
Power Cord Connection ..........................................................................................9
Air Input Connections.............................................................................................10
Output Connections......................................................................................................10
Torch Connection...................................................................................................10
Operating Instructions.........................................................................................................10
Sequence of events......................................................................................................10
Pilot Arc Discussion......................................................................................................11
Procedure Recommendations ......................................................................................11
General ..................................................................................................................11
Thin Gauge Sheet Metal ........................................................................................11
Expanded Metal .....................................................................................................11
Thick Sections of Metal ..........................................................................................12
In All Cases ............................................................................................................12
Suggestions for Extra Utility from the PRO-CUT System.............................................12
Maintenance Procedures ....................................................................................................13
Routine Maintenance....................................................................................................13
Periodic Maintenance ...................................................................................................13
Troubleshooting Procedures...............................................................................................14
Troubleshooting Guide .................................................................................................14
Troubleshooting Steps ........................................................................................15-18
Troubleshooting Tests .........................................................................................19-22
Switch P.C. Board Repairs .................................................................................................23
Switch P.C. Board Replacement Procedures...............................................................23
Replacement of Power Modules and Out put Diodes...................................................23
Environmental Protection .............................................................................................24
PRO-CUT 40 Status Lights Operating Modes ....................................................................24
Procedure for Replacing P.C. Boards.................................................................................25
Wiring Diagram PRO-CUT 40.............................................................................................26
Parts Lists......................................................................................................................Appendix
PRO-CUT 40 Torch and Cable Figure 1 .......................................................................Appendix
�5�
for selecting a QUALITY product by Lincoln Electric. We want you
Thank You to take pride in operating this Lincoln Electric Company product
•â?¢â?? as much pride as we have in bringing this product to you!
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Model Name & Number _____________________________________
Code & Serial Number _____________________________________
Date of Purchase _____________________________________
Whenever you request replacement parts for or information on this equipment always supply the information
you have recorded above.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
�6�
PRODUCT DESCRIPTION hardness control. This is particularly important on
high alloy steels and heat treated aluminum. Job con-
ditions, prevailing codes, alloy level, and other consid-
The PRO-CUTâ„? 40 is a constant current, continuous
erations may also require preheat temperature con-
control plasma cutting system. The machine is invert-
trol. The following minimum preheat temperature is
er based for portability, and is one of the most sophis-
recommended as a starting point. Higher tempera-
ticated on the market. It provides excellent starting
tures may be used as required by the job conditions
characteristics, cutting visibility and arc stability. The
and/or prevailing codes. If cracking or excessive
torch has a patented safety mechanism which
hardness occurs on the cut face, higher preheat tem-
ensures that the consumables are in place before cut-
perature may be required. The recommended mini-
ting can begin. This is extremely important due to the
mum preheat temperature for plate thickness up to 1/2
high voltages involved with the plasma process.
inch is 70 (°F).
The PRO-CUT 40 comes with an air regulator, coarse
USER RESPONSIBILITY
air filter, oil coalescing filter, and pressure gauge. The
system is available with a 25 ft. or a 50 ft. torch cable.
The system is capable of cutting with compressed air Because design, fabrication, erection and cutting vari-
or nitrogen. Nitrogen is typically used to cut aluminum ables affect the results obtained in applying this type
and other nonferrous metals. of information, the serviceability of a product or struc-
ture is the responsibility of the user. Variation such as
The PRO-CUT is controlled by a microprocessor- plate chemistry, plate surface condition (oil, scale),
based system. The machine performs rudimentary plate thickness, preheat, quench, gas type, gas flow
self troubleshooting when powered up, which aids in rate and equipment may produce results different than
field servicing. those expected. Some adjustments to procedures
may be necessary to compensate for unique individ-
PREHEAT TEMPERATURE FOR ual conditions. Test all procedures duplicating actual
field conditions.
PLASMA CUTTING
Preheat temperature control is recommended for opti-
mum mechanical properties, crack resistance and
SPECIFICATIONS
Type K1396-1 (60 Hz) Torch with 25 ft.(7.6 m) Cable
K1396-2 (60 Hz) Torch with 50 ft.(15.2 m) Cable
Input Frequency 60 Hz, 1ø
Output Rating 40 Amps @ 60% Duty Cycle
35 Amps @ 100% Duty Cycle
Pilot Current 8 amps
Pilot Duty Cycle 50% (30 seconds out of 60 seconds)
Current Range 15-40 Amps
Maximum OCV 330
Normal OCV 320
Input Power
Standard Voltages 208/230V
Current 41 Amps/38 Amps @ 60%
34 Amps/32 Amps @ 100%
Idle Current 0.6
Idle Power 140W
Power Factor @ Rated Load 0.64
Net Weight
w/25 ft. (7.6 m) Cable 88 lbs/40 kg
w/50 ft. (15.2 m) Cable 96 lbs/43.4 kg
Dimensions, H x W x D 17.7� x 10.5� x 22.6�
(443 x 267 x 574 mm)
�7�
INSTALLATION
HIGH FREQUENCY INTERFERENCE
PROTECTION
SAFETY PRECAUTIONS
q Read the safety precautions at the beginning of
The PRO-CUT 40 employs a solid state high frequen-
this Operator's Manual before proceeding.
cy torch starting circuit which drastically reduces high
q Only personnel that have read and under-
stood this Operator’s Manual should install and frequency emissions from the machine compared with
operate this equipment. spark gap type high frequency generators.
q Machine must be connected to system ground per
any national, local or other applicable electrical Radiated interference can develop, however, in the
codes. following four ways:
q The power switch is to be in the “OFF� position
when connecting power cord to input power.
(1) Direct interference radiated from the machine.
WARNING (2) Direct interference radiated from the cutting
leads.
TURN THE INPUT POWER OFF USING THE DIS-
CONNECT SWITCH AT THE FUSE BOX BEFORE
(3) Direct interference radiated from feedback into
ATTEMPTING TO CONNECT THE INPUT POWER
the power lines.
LINES.
(4) Interference from reradiation of “pickup� by
� Only qualified personnel should perform this installa-
ungrounded metallic objects.
tion.
Keeping these contributing factors in mind, installing
� Turn the power switch on the PRO-CUT 40 “off�
equipment per the following instructions should mini-
before connecting or disconnecting output cables.
mize problems.
� Connect the PRO-CUT 40 grounding terminal locat-
(1) Keep the machine power supply lines as short as
ed on the side of the case back to a good electrical
possible.
earth ground.
(2) Keep the work and torch leads as short as possi-
WARNING
ble and as close together as possible. Lengths
should not exceed 50� (15.2 m). Tape the leads
DISCHARGE INPUT CAPACITORS BEFORE
together when practical.
WORKING INSIDE MACHINE.
------------------------------------------------------------------------
(3) Be sure the torch and work cable rubber cover-
ings are free of cuts and cracks that allow high
LOCATION frequency leakage.
(4) Keep the torch in good repair and all connections
Place the PRO-CUT 40 where clean cooling air can
tight to reduce high frequency leakage.
freely circulate in through the side louvers and out
through the front opening. Dirt, dust or any foreign
NOTE: The machine frame MUST also be grounded -
material that can be drawn into the machine should be
see paragraph under “Electrical Input
kept at a minimum. Failure to observe these precau-
Connection�. The work terminal ground does
tions can result in excessive operating temperatures
not ground the machine frame.
and nuisance shutdown of the machine. Before plan-
ning the installation, read the next section entitled
(5) When the machine is enclosed in a metal build-
“High Frequency Interference Protection�.
ing, several good earth driven electrical grounds
around the periphery of the building
A source of clean, dry, compressed air or nitrogen
are recommended.
must be supplied to the PRO-CUT 40. Oil in the air is
a severe problem and must be avoided. The supply
pressure must be between 70 and 150 psi (482 and
Failure to observe these recommended installation
1032 kPa). The flow rate is approximately 4.7 cfm
procedures may cause radio or TV interference prob-
(133 l/min.). Failure to observe these precautions
lems and result in unsatisfactory cutting performance
could result in excessive operating temperatures or
resulting from lost high frequency power.
damage to the torch.
�8�
ELECTRICAL INPUT CONNECTION
LIFT MYLAR
INSULATION
WARNING
ELECTRIC SHOCK can kill.
� Disconnect input power before CAPACITOR
TERMINALS
proceeding. d. Use a DC voltmeter to check that voltage is not
present across terminals.
� Have a qualified electrician make
the input connections.
e. Replace discharge resistor onto fan baffle.
� Be sure to discharge capacitors with the
procedure outlined below before working in Input Voltage Setup
that area of equipment.
------------------------------------------------------------
208V INPUT 230V INPUT
Electrical Installation for PRO-CUT 40 208 230 208 230
a. The PRO-CUT 40 should be connected only by a qualified A
A
electrician. Installation should be made in accordance with
the U.S. National Electrical Code, all local codes and the
information detailed below.
H1 H3 H1 H3
b. When received directly from the factory, the dual voltage TERMINAL STRIP 1 TERMINAL STRIP 1
(208-230) machines are internally connected for the highest
voltage (230) input. If 230 is the desired input, then the Power Cord Connection
machine may be connected to the power system without
any setup required inside the machine. A 10-foot power cord is provided and wired into the
machine. Follow the power cord connection instruc-
c. 208 volt operation requires a voltage panel setup: Remove tions. Incorrect connection may result in equipment
roof, discharge input capacitors, and move lead “A� from damage.
�230� to �208� of terminal strip �1�. See following instruc-
tions.
NOTE: Do not power the PRO-CUT 40 off of the auxiliary power
supply of an engine driven welder. If the voltage peaks
from the engine welder exceed 380V the filter capaci- BLACK
tors, FETS of other circuity may fail on the PRO-CUT 40.
GREEN
Capacitor Discharge Procedure
WHITE
a. Locate discharge resistor (25 ohms 25W)
attached to fan baffle. Resistor has no leads
connected to it.
RESISTOR
Install in accordance with all local and national electric
codes.
FAN BAFFLE
RECOMMENDED FUSE SIZES
b. Remove resistor from fan baffle. BASED ON THE U.S. NATIONAL ELECTRICAL CODE
AND MAXIMUM MACHINE OUTPUTS
c. Hold resistor body with electrically insulated INPUT VOLTS* FUSE SIZE IN AMPS
(TIME DELAY FUSES)
glove. DO NOT TOUCH TERMINALS.
1 Phase 208 60
Carefully lift mylar insulation. Connect resistor
60 Hz / 50 Hz 230 60
terminals across two hex head cap screws in
position shown. Hold in position for 1 second.
Repeat for capacitor located on opposite side.
* Input voltage must not exceed ± 10% of rated value.
�9�
Air Input Connections
OPERATING INSTRUCTIONS
WARNING
CYLINDER may explode if damaged
Sequence of events:
� Keep cylinder upright and chained to a
fixed support.
A. Turn on the line power.
� Keep cylinder away from areas where it
may be damaged.
B. Connect the air supply to the machine.
� Never lift equipment with cylinder attached.
� Never allow the cutting torch to touch cylinder.
C. Turn the power switch on.
� Keep cylinder away from live electrical circuits.
� Maximum inlet pressure 150 psig.
-The green “Power On� LED should begin to
------------------------------------------------------------------------
glow.
A source of clean, compressed air or nitrogen must be
-The fan should start.
supplied to the PRO-CUT 40. The supply pressure
must be between 70 and 150 psi (482 and 1032 kPa).
-If the “Safety� LED is glowing, push the “Safety
The flow rate is approximately 4.7 cfm. Oil in the air is
Reset� button. If there is no problem, the LED
a very severe problem and must be avoided.
will go off. If there is a problem, refer to Step 5
of the Test Step Chart , and the Troubleshooting
Remove the plastic thread protector from the regulator
Guide.
input port (located on the back of the machine). Use a
suitable gas connection fitting to make the connection
D. Set the Purge/Run switch to Purge.
to the available air supply. The input port is a 1/4�
NPT thread. Tighten the air fitting to prevent leakage
-The air should start.
but do not overtighten. The use of Teflon tape to seal
the connection is recommended.
-The “Air Pressure� LED should be lit.
Nitrogen from cylinders may be used with this
-Adjust the air regulator for 70 psi (482 kPa).
machine. The cylinder of nitrogen gas must be
equipped with a pressure regulator. No more than
E. Set the Purge/Run switch to Run.
150 psi (1032 kPa) may be supplied to the regulator
on the machine. Install a hose between the regulator
-The air will continue to run for 20 seconds of
on the gas cylinder and the gas inlet on the cutter.
postflow. If the trigger is activated within this
time period, the pilot arc will immediately start.
OUTPUT CONNECTIONS F. When ready to cut, connect the work lead clamp to
the piece to be cut, place the torch near the work,
WARNING make certain all safety precautions have been
HIGH FREQUENCY SHOCK CAN taken and pull the trigger.
CAUSE INJURY OR FALL.
� Keep the cutting torch and cables in -Air will flow for a preflow time of 2 seconds
good condition. and the pilot arc will start. (This is true unless
� Secure yourself in position to avoid a fall. the machine is in postflow, then the preflow time
---------------------------------------------------------------------------- is skipped and the pilot arc will start
immediately.)
Torch Connection -The “Output On� LED will light.
The PRO-CUT 40 comes factory equipped with a cut- -The pilot arc will run for 3.0 seconds and shut
ting torch. Cutting torches come with a 25 ft. (7.6 m) off unless the plasma is brought in contact with
or a 50 ft. (15.2 m) cable. the work and the arc is transferred.
Illustrations of the torch along with the required -When the arc is transferred, cutting begins.
replacement parts are shown in the parts lists as Finish the cut to be made and release the trigger.
P210-E and Figure 1. The ends of the cable to be
connected to the power source are unique. Follow the G. When the trigger is released, the arc will stop.
applicable instructions as given in Figure 1 of the
parts lists. -The air will continue to run for 20 seconds of
postflow. If the trigger is activated within this
� 10 �
time period, the pilot arc will immediately restart. � The S19425-1 Drag Cup is recommended when
the output control is set in the blue range to pro-
tect the torch from dross and improper arcing
WARNING conditions.
ELECTRIC SHOCK CAN KILL.
� Use proper cutting procedures referred to in
� Turn off machine at the disconnect
the Procedures Guidelines.
switch at the back of the machine
before tightening, cleaning or replac
Thin Gauge Sheet Metal:
ing consumables.
------------------------------------------------------------------------
Output set below mid-range.
H. If the “Safety� LED lights at any time, check the following:
� Check the torch consumables. If they are not � The torch should be dragged on the metal sur-
properly in place the machine will not start. face, touching the nozzle lightly to the surface
after piercing a hole. Current control should be
� Check the condition of the inside of the set in the yellow range only.
nozzle. If debris has collected, scrape it out
with a piece of sturdy wire or a suitable drill bit. � The S19425-1 Drag Cup should not be used at
Refer to “Suggestions for Extra Utility from the very low outputs, as it will cause erratic arc
PRO-CUT system�. action.
� After the problem is found, reset the machine � Do not allow the torch cable or body to contact
by pressing the “Safety Reset� button. (It is hot surfaces.
possible for electrical noise to trip the safety
circuit on rare occasions. This should not be � The best cut quality is obtained by reducing the
a regular occurrence.) current to a level that is adequate for the maxi-
mum travel speed.
� If the machine does not reset or continues to
trip, consult the Troubleshooting Section. � Aluminum, copper and other nonferrous metals
typically require more current than the same
thickness of steel.
Pilot Arc Discussion:
The PRO-CUT 40 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 Expanded Metal:
rapid succession, is not recommended. These starts
will generally reduce consumable life. Occasionally,
Output set near mid-range.
the pilot arc may sputter or start intermittently. This is
aggravated when the consumables are worn or the air
pressure is too high. Keep in mind that the pilot arc is
� Cut as you would light gauge sheet metal.
designed to transfer the arc to the workpiece and not
for numerous starts without cutting.
� If the trigger is continuously pressed and
released to obtain the bright pilot arc for long
periods of time, the machine will go into pilot arc
duty cycle limit. This is a 30 seconds out of 60
seconds pilot duty cycle. The pilot arc is dis-
Procedure Recommendations abled in the limit period. Pilot arc duty cycle
limit is indicated by alternately flashing “OUT-
When used properly, plasma arc cutting is a very eco- PUT ON� and “FAULT� LED’s.
nomical process. Improper use will result in a very
high operating cost. � Placing a thin piece of scrap sheet metal above
the area to be cut and cutting through both can
make the job easier.
General
� Do not allow the torch cable or body to contact
� Follow safety precautions as printed inside the hot surfaces.
operating manual and on the machine.
� 11 �
Thick Sections of Metal:
Suggestions for Extra Utility from the
Output set above mid-range.
PRO-CUT System:
� The best quality and consumable life will be � If it becomes absolutely necessary to cut
obtained by holding the torch nozzle off the sur- through a very thick section, the air flow at the
face about 1/8 inch. Output control should be regulator on the back of the machine may be
set in the blue range only. Do not touch the raised to 75 psi (516 kPa) to get a better cut
nozzle to the work or carry a long arc. result, and may give better consumable life. 70
psi (482 kPa) is the recommended pressure in
� Use the S19425-1 Drag Cup to protect the torch. all situations.
The only reason not to use the Drag Cup when
the output control is in the blue region, is in
special tight corners. Always hold at least a 1/8�
WARNING
standoff in those situations.
ELECTRIC SHOCK CAN KILL.
� Set the current to the minimum necessary to
Turn off machine at the disconnect switch at the back
make the cut.
of the machine before tightening, cleaning or replacing
consumables.
� Pierce the plate by slowly lowering the torch
------------------------------------------------------------------------
onto it at an angle of about 30° to blow the
dross away from the torch tip and slowly rotate
� The PRO-CUT 40 will cut with consumables that
the torch to a vertical position as the arc
are worn considerably. Many competitive sys-
becomes deeper.
tems require replacement consumables long
before a PRO-CUT system does. This is
� Where possible, start the cut from the edge of
because of the solid state current regulation that
the workpiece.
the PRO-CUT has. Also, the safety reset circuit
provides a means of extending nozzle life.
� Keep moving! A steady speed is necessary. Do
not pause.
Sometimes a small piece of material breaks off
from the electrode and bridges the gap between
� Do not allow the torch cable or body to contact
the nozzle and the electrode. In a competitive
hot surfaces.
unit, this would often result in the destruction of
the electrode and nozzle due to overheating.
In All Cases:
This will result in the tripping of the PRO-CUT
safety circuit. When this happens, turn the
� Do not carry a long arc. This may trip the safety power off, remove the nozzle and scrape any
or fault circuits and wears consumables rapidly. debris from its inside cavity with a piece of stur-
dy wire or a suitable drill bit. Replace the noz-
� Always hold a standoff while cutting. zle, turn on the power and continue cutting.
� Use the proper machine setting. Cranking the � The PRO-CUT 40 is capable of operation with a
machine to maximum output will not produce 50 ft. (15.2 m) plasma torch. Pilot arc operation
the best cutting performance in most situations. may be slightly degraded with this torch
installed. Sputtering may occur after the pilot
� Use proper cutting procedures referred to in the arc is established and occasionally the pilot arc
Procedures Guidelines. may not light after the trigger is depressed.
Neither cutting performance nor machine relia-
� Use the nozzle with the largest orifice size that bility will be lessened by this condition. Keep in
gives an acceptable cut. This will improve parts mind that the condition of the consumables and
life. air pressure level have a large impact on pilot
arc ignition.
� Tighten the nozzle for a snug fit using the
S18808 wrench included in the PCT 40 tool box.
Do not use pliers or overtighten.
� 12 �
MAINTENANCE PROCEDURES 5. Check the filter elements every several months
to see if they are clogged (weekly in very dirty
environments). Replace if necessary.
WARNING
ELECTRIC SHOCK CAN KILL. 6. Inspect the cable periodically for any slits or
puncture marks in the cable jacket. Replace if
BEFORE PERFORMING ANY MAINTE-
necessary. Check to make sure that nothing is
NANCE THAT REQUIRES OPENING
crushing the cable and blocking the flow of air
THE CASE OF THE POWER SOURCE:
through the air tube inside. Also, check for
kinks in the cable periodically and relieve any so
� Disconnect input power to this machine at the
as not to restrict the flow of air to the torch.
Disconnect switch and discharge input capacitors
before working inside machine.
WARNING
� Do not touch electrically live parts or internal wiring.
ELECTRICAL SHOCK CAN KILL.
Turn off machine at the disconnect switch at the back
� Only qualified personnel should service this
of the machine before tightening, cleaning or replacing
machine.
consumables.
------------------------------------------------------------------------
------------------------------------------------------------------------
Change consumables as required.
ROUTINE MAINTENANCE
PERIODIC MAINTENANCE
1. Keep the cutting area and the area around the
machine clean and free of combustible materi- Thermal Protection
als. No debris should be allowed to collect
which could obstruct air flow to the machine. Two thermostats protect the machine from excessive
operating temperatures. Excessive temperatures may
2. Every 6 months or so, the machine should be be caused by a lack of cooling air or operating the
cleaned with a low pressure airstream. Keeping machine beyond the duty cycle and output rating. If
the machine clean will result in cooler operation excessive operating temperature should occur, the
and higher reliability. Be sure to clean these yellow thermal LED will light and the thermostat will
areas: prevent output voltage or current.
� Power, Driver, Switch, and Control printed Thermostats are self-resetting once the machine cools
circuit boards sufficiently. If the thermostat shutdown was caused
by excessive output or duty cycle and the fan is oper-
� Power switch ating normally, the Power Switch may be left on and
the reset should occur within a 15 minute period. If
� Main Transformer the fan is not turning or the air intake louvers were
obstructed, then the power must be switched off for 15
� Input Rectifier (located on fan baffle) minutes in order to reset. The fan problem or air
obstruction must also be corrected.
3. Examine the sheet metal case for dents or
breakage. Repair the case as required. Keep
the case in good condition to assure 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 filters to be sure they do
not become clogged. The first stage of the air
filter on the machine is self draining and will
stop most of the water in the air line. The sec-
ond stage of the filter is also self draining and
will stop almost all of the oil in the line as well as
particulate matter. Both stages will drain auto-
matically when the flow rate changes rapidly.
� 13 �
TROUBLESHOOTING PROCEDURES TROUBLESHOOTING GUIDE
WARNING
WARNING
ELECTRICAL SHOCK CAN KILL.
ELECTRIC SHOCK CAN KILL. Turn off machine at the disconnect switch at the back
BEFORE PERFORMING ANY MAINTE- of the machine before tightening, cleaning or replacing
NANCE THAT REQUIRES OPENING consumables.
THE CASE OF THE POWER SOURCE: ------------------------------------------------------------------------
� Disconnect input power to this machine at the
Disconnect switch and discharge input capacitors
before working inside machine.
Visual Inspection
� Do not touch electrically live parts or internal wiring.
Clean interior of machine with a low pressure
airstream. Make a thorough inspection of all compo-
� S1 power switch, D9 input rectifier, C1 and C2
nents. Look for signs of overheating, broken leads or
capacitors, Switch PC boards, R1, R2, R3, R4, and
other obvious problems. Many problems can be
R5 resistors and T2 main transformer are all
uncovered with a good visual inspection.
connected to the main lines. Use care when
making voltage measurements.
� Do not troubleshoot the machine with an
Test Conditions
oscilloscope. Do not use electrical test equipment
which has one test probe in common with the
Perform all tests at rated input voltage. Make ohmme-
equipment case or grounding pin of the 115 VAC
ter checks only after power has been disconnected
power plug. Use a battery power VOM for all
from machine and after capacitors have been dis-
troubleshooting.
charged.
� Only qualified personnel should service this
Certain high voltage connections have been insulated
machine.
with RTV sealant. It is necessary to break through the
------------------------------------------------------------------------
sealant with a sharp probe in order to make voltage or
resistance checks.
HOW TO USE THIS GUIDE: Carefully read through
each applicable section listed below. Remember that
most problems are caused by improper setup, such as
switch settings, control settings, etc.
If you believe the set up is correct and the trouble still
exists, first check for the obvious: input power, blown
fuses, loose PC board connectors, broken wires and
the like. The sections listed below are intended to
help you find the less obvious sources of trouble.
� 14 �
SYMPTOM CHECK
No LED’s light and the fan does not operate when 1. Check the input power to be sure it is on.
the power switch is turned on. 2. Check the power line fuses and machine
connection.
3. Replace line switch.
No LED’s light when the power switch is turned 1. Disconnect plug P5 from jack J5 at the
on, but the fan operates. auxiliary transformer, T1, and check that
18VAC is present between J5-1 (blue wire)
and J5-2 (blue wire). Replace the trans-
former, T1, if the voltage is not within spec-
ifications. Reconnect plug P5 to jack J5.
2. Check for 15VDC being present between J6-6
(+, lead number 302) and J6-1 (-, lead
number 275D). Replace the POWER BOARD
if voltage is low.
3. Check for 5.5VDC being present between
J2-8 (+, lead number 808) and J2-2 (-, lead
number 802). Replace the MICRO CONTROL
BOARD if voltage is low. Replace the STATUS
BOARD if voltage is OK.
The “MACHINE ON� LED is lit, but there is no 1. Check the air supply to the machine. If the
response when the trigger is pulled. If another air does not flow, the machine will not start.
LED or combination of LED’s are on or blinking, The “AIR PRESSURE� LED must be lit when
refer to the section under that combination. air is flowing.
2. Check for proper TRIGGER SWITCH operation.
There should be continuity between J20-2 and
J20-4 when the trigger switch is depressed and
no continuity when the switch is not depressed.
Replace the trigger switch if defective.
3. Check for greater than 4VDC between J16-2
(+, lead number 502) and J16-1 (-, lead number
501) when the trigger switch is depressed (the
voltage should be 0 otherwise). If the voltage
is not correct, replace the PWM CONTROL
BOARD.
4. Check the operation of the air solenoid by
switching the machine to “PURGE�. If the
pressure is sufficient, the air should begin to
flow and the “AIR PRESSURE� LED should
turn on.
A. If the air does not flow and the “AIR
PRESSURE� LED does not light, check the
following:
1. Check the 115VAC between J5-9 (lead
number 215) and J5-6 (lead number
215A) at the auxiliary transformer, T1.
If voltage is not correct, replace the
transformer, T1.
2. Check for 115VAC between J18-1 (lead
number 215C) and J18-4 (lead number
215A or 215B) at the air solenoid.
a. If there is not 115VAC between J18-1
and J18-4, check for <0.5VDC
between J1-5 (+, lead number 505)
and J1-1, (-, lead number 501).
Replace the PWM CONTROL BOARD
if the voltage is OK, or replace the
MICRO CONTROL BOARD if the volt-
age is high.
� 15 �
SYMPTOM CHECK
b. If there is 115VAC between J18-1 and
J18-4, check for less than 0.5 VDC
between J5-5 (+, lead number 255A or
255B) and J5-2 (-, lead number 272).
If voltage is OK, replace the air
solenoid. If voltage is high, (approx.
5.5 VDC), replace the pressure switch.
B. If the air functions properly in “PURGE�,
switch the machine back to the “RUN� mode.
The air should continue to flow and the “AIR
PRESSURE� LED should remain on for 5 to
20 seconds. If air now functions properly,
replace the MICRO CONTROL BOARD. If
the air does not function properly, perform
step 4.A.2.
The air begins to flow, the “OUTPUT ON� LED lights 1. Check the torch consumables to be sure they
for a brief period and then the “MALFUNCTION� LED are in tight, not dirty or greasy, and in good
turns on until the trigger is released. No arc is shape. Replace the consumables if necessary.
established. 2. Check for 380VAC between leads H4 and H1
at the auxiliary transformer, T1. Replace the
transformer, T1, if not correct.
3. Check for 115VAC between J5-9 (lead number
215) and J5-6 (lead number 215A) at the auxil
iary transformer, T1. If voltage is not correct,
replace the transformer, T1.
4. Check for 115VAC between J19-9 (lead number
215B) and J19-7 (lead number 215D) at the
high frequency module. 115VAC should be
applied for approximately 1/2 second while the
“OUTPUT ON� LED is turned on.
A. If there is not 115VAC between J19-9 and
J19-7, check for < 0.5 VDC between J16-4
(+, lead number 504) and J16-1 (-, lead
number 501). Replace the PWM CONTROL
BOARD if the voltage is OK, or replace the
MICRO CONTROL BOARD if the voltage
remains high, approximately 15 VDC.
B. If there is 115VAC between J19-9 and J19-7
check for less than 0.5 VDC between J5-5
(+, lead number 255A or 255B) and J5-2
(-, lead number 272). If voltage is OK,
replace the air solenoid. If voltage is high,
approximately 5.5 VDC, replace the
pressure switch.
5. Check for a high frequency enable signal be-
tween J3-1 (+, lead number 327) and J1-1 (-,
lead number 501). The signal should be a 15V
square wave at a 60 Hz frequency for approx.
1/2 second while the “OUTPUT ON� LED is
turned on. If the signal remains high (+15 VDC)
replace the MICRO CONTROL BOARD. If the
enable signal is present, replace the HIGH
FREQUENCY MODULE.
6. Check pilot to work for a value between 6 and
10 ohms of resistance.
7. Check each 300W resistor for its rated value.
Replace if bad.
8. Replace PWM CONTROL BOARD.
9. Replace MICRO CONTROL BOARD.
� 16 �
SYMPTOM CHECK
The air begins to flow, the “OUTPUT ON� LED 1. Check the torch consumables to be sure they
lights for a brief period and then the are in tight, not dirty or greasy, and in good
“MALFUNCTION� LED begins blinking. No arc is shape. Replace the consumables if necessary.
established. 2. Check the torch consumables to see if they are
melted together or are simply touching each
other. Tighten, clean or replace as needed.
3. Check the torch cable to see if it is cut or
punctured. Replace it as needed.
4. Check electrode to pilot for a short.
5. Check the output diodes. Perform test step 3.
6. Check the SWITCH PC BOARDS. Perform
test steps 1 and 2 for BOTH SWITCH PC
BOARDS, and perform test steps 4A and 4B.
7. Check for an open circuit in the electrode
and work leads.
8. Replace the PWM CONTROL BOARD.
9. Replace the MICRO CONTROL BOARD.
The air begins to flow, the ‘OUTPUT ON� LED 1. Check the torch consumables to be sure they
lights for a brief period and then the “MALFUNCTION� are tight, not dirty or greasy, and in good shape.
LED begins blinking. There was a brief arc. Replace the consumables if necessary.
2. Replace the PWM CONTROL BOARD.
3. Replace the MICRO CONTROL BOARD.
The arc starts but sputters badly. 1. Check the torch consumables to be sure they
are tight, not dirty or greasy and in good shape.
Replace if necessary.
2. Check air supply for oil or a great deal of water.
If there is oil or a great deal of water, the air
must be filtered or the machine switched to
nitrogen or bottled air.
Poor cutting, cutting settings drift or output 1. Check front panel wiring and controls.
power is low. 2. Replace the PWM CONTROL BOARD.
3. Replace the MICRO CONTROL BOARD.
Main fuses open or Switch PC Boards appear 1. Perform test steps 1 and 2 for both Switch PC
overheated boards, and perform test step 5.
Output power is low. Machine makes squealing 1. Perform test steps 1 and 2 for both Switch
noise while under load. Machine is connected PC Boards, and perform test steps 4A and 4B.
for 208/230V or 220V.
The “THERMAL� LED is lit. The “MALFUNCTION� 1. The machine is overheated. Allow it to cool and
LED is blinking. reset. The air intakes of the machine must not
be blocked, or this will become a nuisance
� 17 �
SYMPTOM CHECK
The “MALFUNCTION� LED is lit. 1. The MALFUNCTION circuit monitors the torch
to see if it is shorted as well as internal machine
failures.
2. Check the torch consumables to see if they are
melted together or are simply touching each
other. Tighten, clean or replace. See
“Suggestion for Extra Utility from the PRO-CUT
System�.
3. Check the torch cable to see if it is cut or
punctured. Replace.
4. Turn off the machine and turn it back on. If the
“MALFUNCTION� LED will not stay off when you
try to cut again and there is no problem with the
torch, then something has failed in the machine
and the machine should not be left on.
A. Check electrode to pilot for short.
B. Check airflow.
C. Check the power board. During preflow,
there should be no voltage between work a
and electrode and at end of preflow open cir-
cuit voltage should be present. Replace if
bad.
5. Replace PWM CONTROL BOARD.
6. Replace MICRO CONTROL BOARD.
Alternating “AIR/MALFUNCTION� LED lights 1. Replace MICRO CONTROL BOARD.
The “SAFETY� LED is lit. 1. The machine will not operate. The machine
senses that the nozzle is not in place, or the
operators could be exposed to dangerous
voltages if the machine were allowed to operate.
2. Check the nozzle to be sure it is tightly in place.
3. Check the torch consumables to see if they are
melted together or are simply touching each
other. Tighten, clean or replace. See
“Suggestion for Extra Utility from the Pro-Cut
System�.
4. Check the torch cable to see if it is cut or
punctured. Replace.
5. Check to see that the torch is hooked to the
machine properly.
6. Push the ‘SAFETY RESET� button, the LED
should go out.
7. This circuit rarely trips on power up or because
of noise. If the circuit can be reset, it is OK to
continue operation.
8. Replace PWM CONTROL BOARD, as this is a
safety problem.
The “OUTPUT ON� and “MALFUNCTION� LED’s 1. The pilot arc duty cycle has been exceeded.
blink in alternating order. The machine will cool down and the lights will
quit blinking in about 30 seconds. The pilot arc
is limited to 30 out of 60 seconds.
� 18 �
TEST STEPS
Step Test Check * Test Result Conclusion Next Repair Action
Test
Step
1 FET A1 in circuit Terminals on
test Switch PC
Board: 1/8 (pos) >1K ohms FET OK
to 12 (neg)
<100 ohms Short 4A Replace
Switch PC
Remove leads Board
4/5 and 1/8 from
Switch PC Board
1/8 (neg) to 12 <100 ohms FET OK
(pos)
>1K ohms FET Open 4A Replace
Switch PC
Board
2 FET A2 in circuit
test
Terminals on
Switch PC
Board:
9 (pos) to 4/5
(neg) >1K ohms FET OK
<100 ohms Short 4A Replace
Switch PC
Remove leads Board
4/5 and 1/8 from
Switch PC Board 9 (neg) to 4/5 <100 ohms FET OK
(pos)
>1K ohms FET Open 4A Replace
Switch PC
Board
3 Output Diodes Remove output <100 ohms Shorted output Test individu-
load. diode (D1 or D2) ally
+ work to - elec-
trode >500 ohms Output diodes
OK
� 19 �
Step Test Check * Test Result Conclusion Next Repair Action
Test
Step
4A Snubber resis- Disconnect leads
tors 401 thru 404 on
Switch PC
Boards. Measure 25 ohms R4 OK
across leads: high resistance R4 open Replace R4
401 to 12
25 ohms R5 OK
402 to 9 high resistance R5 open Replace R5
25 ohms R2 OK
403 to 12 high resistance R2 open Replace R2
25 ohms R3 OK
404 to 9 high resistance R3 open Replace R3
4B Snubber diodes Disconnect all
leads except
R&W on Switch
PC Board.
Measure across
terminals on
Switch PC
Board:
9 (neg) to 1/8 <100 ohms OK
(pos) >1K ohms Open Replace Switch
PC Board
9 (pos) to 1/8 >1K ohms OK
(neg) <100 ohms Short Replace Switch
PC Board
12 (neg) to <100 ohms OK
401/403 (pos) >1K ohms Open Replace Switch
PC Board
12 (pos) to >1K ohms OK
401/403 (neg) <100 ohms Short Replace Switch
PC Board
402/404 (neg) to <100 ohms OK
9 (pos) >1K ohms Open Replace Switch
PC Board
402/404 (pos) to >1K ohms OK
9 (neg) <1K ohms Short Replace Switch
PC Board
4/5 (neg) to 12 <1K ohms OK
(pos) >100 ohms Open Replace Switch
PC Board
4/5 (pos) to 12 >1K ohms OK
(neg) <100 ohms Short Replace Switch
PC Board
� 20 �
Step Test Check * Test Result Conclusion Next Repair Action
Test
Step
5 D9 Input 13 (pos) to T1
Rectifier (neg) >1K ohms OK
<100 ohms Shorted 1-2 Replace D9 In
space S1 Test
C1 and C2
13 (pos) to T2
(neg) >1K ohms OK
Replace D9
<100 ohms Shorted 1-2 Inspect S1
Test C1 and
C2
13 (pos) to T3
(neg) (3 phase >1K ohms OK
only)
Replace D9
<100 ohms Shorted 1-2 Inspect S1
Test C1 and
C2
12 (neg) to T1
(pos) >1K ohms OK
Replace D9
<100 ohms Shorted 1-2 Inspect S1
Test C1 and
C2
12 (neg) to T2 >1K ohms OK
(pos)
Replace D9
<100 ohms Shorted 1-2 Inspect S1
Test C1 and
C2
� 21 �
Step Test Check * Test Result Conclusion Next Repair Action
Test
Step
5 (con’t) 12 (neg) to T3
(pos) >1K ohms OK
(3 phase only)
<100 ohms Shorted 1-2 Replace D9
Inspect S1
Test C1 and
C2
13 (neg) to T1
(pos) <100 ohms OK
>1K ohms Open 1-2 Replace D9
Inspect S1
Test C1 and
C2
13 (neg) to T2 <100 ohms OK
(pos)
>1K ohms Open 1-2 Replace D9
Inspect S1
Test C1 and
C2
13 (neg) to T3
(pos) <100 ohms OK
(3 phase only)
>1 K ohms Open 1-2 Replace D9
Inspect S1
Test C1 and
C2
12 (pos) to T1
(neg) <100 ohms OK
>1K ohms Open 1-2 Replace D9
Inspect S1
Test C1 and
C2
12 (pos) to T2
(neg) <100 ohms OK
>1K ohms Open 1-2 Replace D9
Inspect S1
Test C1 and
C2
12 (pos) to T3 <100 ohms OK
(neg)
(3 phase only) >1K ohms Open 1-2 Replace D9
Inspect S1
Test C1 and
C2
� 22 �
SWITCH PC BOARD REPAIRS 9) Carefully holding the Switch PC board, install the
4 socket headcap screws but do not tighten
them. Next, install the 2 hex headcap screws
If a test indicates that one or more FET’s are defec- into the capacitor but do not tighten them.
tive, both Switch PC boards must be replaced. A
defective FET is likely to damage other devices in the 10) Torque the 4 socket head cap screws to 44� lbs.
power circuitry. The defect may be subtle and not and then torque the 2 hex head cap screws to
detectable by ohmmeter measurement. Unknown 50-60� lbs.
defective parts may cause newly replaced parts to fail.
11) Reconnect the leads to the Switch PC boards
In addition to replacing Switch PC boards, replace C1 and reinstall the sheet of mylar insulation.
and C2 if the following conditions are met:
CAUTION
1.Switch PC boards have burned areas.
Before applying power to the machine, check all
a)Switch PC Board Replacement Procedure connections. An incorrect connection will
result in machine damage when power is
WARNING switched on.
------------------------------------------------------------------------
ELECTRIC SHOCK CAN KILL.
12) Connect an ohmmeter set for X1000 to the hex
BEFORE PERFORMING ANY MAINTE-
head screw terminals on the Switch PC board.
NANCE THAT REQUIRES OPENING
The meter will show the capacitors charging up.
THE CASE OF THE POWER SOURCE:
The meter may take a minute or so to stabilize.
The value must not exceed 8000 ohms.If the
� Disconnect input power to this machine at the
meter reads less than 6000 ohms, reverse the
Disconnect switch and discharge input capacitors
meter leads and repeat the test. If OK, proceed
before working inside machine.
with power tests.
� Do not touch electrically live parts or internal wiring.
13) Fuse input supply with 5 amp fuses.
� Only qualified personnel should service this
14) Disconnect P19 from J19 at the high frequency
machine.
module. Check output open circuit voltages dur-
------------------------------------------------------------------------
ing first 1/2 second of output. Do not apply out-
1) Remove the sheet of mylar insulation. put lead.
2) Carefully disconnect the leads at the top of the 15) Fuse for 20 amps and test under load.
Switch PC board.
Replacement of Power Modules and
Output Diodes
3) Remove the 4-socket head cap screws with a
3/16� hex key wrench. Input rectifier, D9 and A1 and A2 of each Switch PC
board are power modules. When mounting power
4) While holding the Switch PC board, remove the 2 modules, the heat sink and module material mounting
hex head cap screws from the center of Switch surface should be clean and free of burrs and foreign
PC board. material. For A1 and A2, apply an even coating of
joint compound to both the heat sink and module
5) Remove board. mounting surfaces. The joint compound should be,
ideally, .002� per surface to eliminate all air pockets.
6) Thoroughly clean the heat sink surface. This may be verified by mounting and then removing
the module. When removed, the compound on both
7) Apply a thin layer (ideally .002�) of Dow 340 heat surfaces will appear textured as if a vacuum had cre-
sink compound to the copper bars on the Switch ated veinlike ridges when the parts were separated. If
PC board and also to the 2 capacitor terminals. the compound does not have this appearance, apply
Keep heat sink compound off of threads since more joint compound and recheck.
this will affect the torque specifications.
Replacement of output diodes D1 and D2 is similar.
8) Carefully place the Switch PC board onto the Clean and brighten mounting surfaces with fine steel
heat sink, being sure the 4 mounting holes are wool. Compound should be used on surface between
lined up before making full contact with the heat diode and heat sink when mounting individual diodes.
sink. DO NOT apply on diode stud and mounting nut
threads.
� 23 �
Components must have proper torque applied to Environmental Protection
mounting screws and to electrical terminals. Torque
the modules according to the following: High voltage connections are covered with an RTV
sealant to prevent malfunction in severe environ-
COMPONENT TO HEAT SINK TERMINAL ments. Sealant must be applied to connections which
COMPONENT TORQUE ± 10% TORQUE ± 10% have been opened or otherwise lost their protection.
------------------------------------------------------------------------------------------------------------------------
A noncorrosive electronic grade sealant such as Dow
A1, A2 44 Inch-Lbs.* N.A.
Corning 3140, 3145, 738, Columbus Adhesives 0172
(M16100-1, -2)
or GE RTV-162 is recommended. Sealant may also
be purchased from Lincoln Electric (order E2519
Input Diode 6 Inch-Lbs. ** 26 Inch-Lbs.
Silicone Rubber RTV coating). Apply sealant after the
(M15454-1)
machine is repaired and tested.
Output diode 25 Inch-Lbs. N.A.
(M15482-3) High voltage areas which require sealant are listed:
------------------------------------------------------------------------------------------------------------------------
* Re-torque after 3 hours to allow for spread of compound.
- PC boards requiring protection are supplied
** Tighten in staggered fashion one quarter turn at a time.
from Lincoln Electric with required protection.
- Input rectifier D9, all 5 terminals.
- Output rectifiers, D1 and D2.
The Power Switch requires tape over connection
areas and contact openings to minimize dirt build up.
PRO-CUT 40 STATUS LIGHTS OPERATING MODES:
STATUS LIGHTS CONDITION SUGGESTIONS
MACHINE ON Should always be on when machine is on. Normal
OUTPUT ON On when there is voltage potential at the torch (cutting or pilot) Normal .
OUTPUT ON is blinking alternately with AIR PRESSURE when There is a problem with the microprocessor,
power is first applied to machine. replace the control PC board.
OUTPUT ON is blinking alternately with MALFUNCTION. Wait for machine to cool.
AIR PRESSURE On whenever the air pressure is above 60 psi (413 kPa), there Normal conditions are purge, preflow, postflow and
is an error condition mentioned above where air will turn on. cutting.
THERMAL Should normally be off. If on, wait for machine to cool down.
MALFUNCTION Light on. At end of preflow, machine checks to see if the torch Check consumables, replace as needed. Check torch
is shorted. cable to see if it is punctured or cut.
Light blinking. If cutting tried with air pressure less than 60 psi No air connecter to machine, air pressure set too low,
(413 kPa), the machine will wait for air pressure to become or air leak in system.
greater than 60 psi (413 kPa).
Light blinking alternately with OUTPUT ON. Pilot arc duty cycle has been exceeded. Wait for
machine lights to stop blinking.
Light turned on during cutting. There is an overcurrent If cutting with standoff more than 1/8� at high range
condition caused by a surge of current the machine was not of machine and nozzle is accidentally touched
designed to handle. Release the trigger and resume cutting. to work, shorten stickout, or use drag cup.
Check consumables to see if electrode is melted to
nozzle.
Light blinking with THERMAL light on. Wait for machine to cool.
� 24 �
STATUS LIGHTS CONDITION SUGGESTIONS
Safety It is possible that this light could turn on when power is first If machine can be reset, it is OK to continue operation.
applied to machine.
The nozzle is not in place. Securely fasten nozzle in place.
While cutting if the voltage between the nozzle and By pressing reset, the machine will be functional.
the work is too high, it will put the machine into SAFETY. This occurs most often when the consumables
are wearing out. By removing the hafnium that
builds up on the inside of the nozzle, it is possible
to extend the life of the consumables.
If the cable is punctured or cut, it can trip the SAFETY. By pressing reset, it will clear the SAFETY. When
cutting is tired again, the machine will either go into
MALFUNCTION or SAFETY; until that time, the
machine will not indicate a malfunction.
-----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
PROCEDURE FOR REPLACING PC BOARDS
Before replacing a PC board which is suspected of
being defective, visually inspect the PC board in ques-
tion for any damage to any of its components and
conductors on the back of the board.
If there is no visible damage to the PC board, install a
new one and see if this remedies the problem. If the
problem is remedied, reinstall the old PC board to see
if the problem still exists. If it does no longer exist
with the old PC board:
1. Check the PC board harness conductor pins for
corrosion, contamination or looseness.
2. Check leads in the plug harness for loose or
intermittent connection.
If PC board is visibly damaged electrically (compo-
nents burned, copper traces opened or damaged),
before possibly subjecting the new PC board to the
same cause of failure, check for possible shorts,
opens or grounds caused by:
1. Frayed or pinched lead insulation.
2. Poor lead termination, such as a poor contact or
a short to adjacent connection or surface.
3. Two or more leads shorted together.
4. Foreign matter or interference behind the PC
boards.
If PC board is visibly damaged mechanically (such as
a part vibrated off or was crushed), inspect for cause,
then remedy before installing a replacement PC
board.
If there is damage to the PC board if replacing PC
board corrects problem, return it to there local Lincoln
Electric Field Service Shop.
� 25 �
CHOKE
L3 WORK
229
T2 12 12
229B
D2
R12
R13
MAIN C7 300W 300W
N.F.
TRANSFORMER .0047/1400
9
9B
B2 C9
9B
4
4, 5 4 .0047/1400
B1
F
404
R3 402, 404
TOP C8
25
+ OUTSIDE .1/400 TORCH CONN. PANEL
C6
25W C2 SWITCH
+
7500 S 20K
(TOP)
R1
.68/400 PILOT
R10
25W BOARD 5W
25 S S
1600 F
ELECTRODE
BOTTOM
25W SNUBBER
TOP
450V - L4
INSIDE OUTSIDE BOARD
401, 403
R2 403 CHOKE 1
1
F F HF TRANSFORMER
12 1, 8 1 1
R W
R
W
2
2
N.D.
12 12 F F
S 3
3
BOTTOM
13
S1
T4 F S 4
4
INSIDE B W
13
POWER S
J20
9B (BOTTOM)
CR1
ON 607A 608A
OFF N.E.
AC1 + N.O. W W
R R
CR2
H1
T1
L1 TP1 N.O.
DRIVER 1
6 3 4 25 AIR SOLENOID
13 J8 SV1
J9
BOARD 215C 1
13 J10
TP3 215A
24
13
INPUT T2 AC2 6
L2 25 1
3 4 4
215B
PER CR3
272 W
2
N.A. N.O.
AC3 TP2 W R W R 255A R
5
308
307
CR4 LOCKED FAN PRESSURE
9A
D9
T3
L3 T3 3
255B
N.O. S6
THERMOSTAT SWITCH
N.E. CURRENT
- Y
6
309 S
INPUT 310 TRANSFORMER
12 TOP 224B J18
I
G A RECTIFIER
12 INSIDE
F B3
9
9A
5
4, 5 5 150 5W
F
9A F
W W
R R 224A
I R14
BOTTOM 8
BOTTOM
402
R5 402, 404
OUTSIDE OUTSIDE 327 604
1
25
+ S S 603
328 2
25W S4
C1 20K 5W
SWITCH
+
6
255C
S R15
BOARD
25 1600 F TOP 5
25W 271
450V - INSIDE
S3 4 608
R4 401 401, 403
F C5
3
12 1, 8 8 8 OUTPUT 5/660VAC
215B 602
9
WIRING DIAGRAM - PROCUT 40
12
12 RECTIFIER 255B
HIGH FREQ MODULE
215D 601
7
THERMOSTAT 608A
D1
J19
607 607A
H1 606
H1
U
H1 9 215
U 605
H4
A N.C. 215A
6
TS1 W
W
5
H2 W
24V 115V
W
4
230
208 O 2 306
7
307
R
8
FAN O 8
308 305
7
24V
R
7
MOTOR H3 Y 309
N.E. 302
6
2
� 26 �
U
H2 H3 2
310 303
4 3
J7
18V
SAFETY
U 304
5
Y 8 10
1 327
303 1 1 S5
1 U J6 RESET
6
U 275D
1 5
328
304 2 2
2
J5 1
311 W
H4 R W
4
1 PURGE/RUN
77A
304 3 3
3 FOR
224A
5
312 3 255/255A
276
7
4 4 4 TESTING
2 S2
B W J12
R
9 270
ONLY
T1 306 275A 5 5
5
POWER J4
224B
10
AUXILIARY 305 6 6
6
BOARD CW (MAX.)
TRANSFORMER 77A
B 7 7
275D
4
215D 1
J3
8 W 8 8
2
R11
9
9
276
215 3
J17 10K
10 10
270
4 275A 2W
NOTES: HF FILTER BOARD R11
11
271
215C 5
CONTROL OUTPUT CONTROL
N.A. INPUT CORD MAY BE PRESENT FOR CONNECTION TO SUPPLY CIRCUIT 12
272
1 6
BOARD
CONNECT GREEN LEAD OF INPUT CORD TO GROUND OR GROUND TERMINAL PER NATIONAL 13
255
2
ELECTRICAL CODE. 801
1 1
GND 14
1A
1 1 302
2 3 STATUS
802
2 2
2 2 BOARD
4 501 1
1
803
3 3
2A
3 3
5
N.B. SINCE COMPONENTS OR CIRCUITRY OF A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT 502 2
2
804
4 4
SHOW THE EXACT COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER. 2A
4 4
3 6 503 3
3 J2 J31
805
5 5
5
5 5
7 504 4
4
J32 J14 806
6 6
N.C. CONNECT LEAD "A" TO TERMINAL 208 FOR 200V-208V INPUT, 3A
6 6
8
229B 3A 505 5
5
807
7 7
J33
OR TERMINAL 230 FOR 220V-230V INPUT. 7 7
9 6
6 J1
J16 808
8 8
229A 4A
8 8
10 507 7
7
N.D. THREE PHASE UNITS CONTAIN T2, AC2, TP1 & TP2.
9 9
4 11 508 8
8
10
10 10
4A
12
N.E. LEADS ARE SHOWN AS TWISTED PAIRS. 509 9
9
MICRO
11
13 510 10
10 CONTROL
N.F. EARLIER VERSIONS USED 20 OHM RESISTOR FOR R12 & R13. 1A
12
1 14 BOARD
511 11
11
12
12
J15 J8 J9, J10, J13, J17 J4, J6, J14
J2, J7, J12, J31
COLOR CODE: 513 13
13
J18 J5, J19
B = BLACK 514 14
14
J13
G = GREEN 15
15
123456
R = RED 516 16
16
W = WHITE J1, J16
J33 J3,J32
Y = YELLOW W W 229A
U = BLUE
CONNECTOR CAVITY NUMBERING SEQUENCE
O = ORANGE
(VIEWED FROM COMPONENT SIDE OF BOARD)
ELECTRICAL SYMBOLS PER E1537
2-24-95D
L8279
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. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number..
Now Available...12th Edition New Lessons in Arc Welding
The Procedure Handbook of Arc Welding Lessons, simply written, cover manipulatory techniques;
With over 500,000 copies of previous editions published machine and electrode characteristics; related subjects,
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q Do not touch electrically live parts or q Keep flammable materials away. q Wear eye, ear and body protection.
WARNING electrode with skin or wet clothing.
q Insulate yourself from work and
ground.
Spanish
q No toque las partes o los electrodos q Mantenga el material combustible q Protéjase los ojos, los oÃdos y el
AVISO DE bajo carga con la piel o ropa moja- fuera del área de trabajo. cuerpo.
da.
PRECAUCION q Aislese del trabajo y de la tierra.
French q Ne laissez ni la peau ni des vête- q Gardez à l’écart de tout matériel q Protégez vos yeux, vos oreilles et
ments mouillés entrer en contact inflammable. votre corps.
ATTENTION avec des pièces sous tension.
q Isolez-vous du travail et de la terre.
German q Berühren Sie keine stromführenden q Entfernen Sie brennbarres Material! q Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
WARNUNG Körper oder feuchter Kleidung!
q Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese
q Não toque partes elétricas e elec- q Mantenha inflamáveis bem guarda- q Use proteção para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
ATENÇÃO da.
q Isole-se da peça e terra.
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-
STELLERS. DIE UNFALLVERHÃœTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
q Keep your head out of fumes. q Turn power off before servicing. q Do not operate with panel open or
WARNING
q Use ventilation or exhaust to guards off.
remove fumes from breathing zone.
Spanish
q Los humos fuera de la zona de res- q Desconectar el cable de ali- q No operar con panel abierto o
AVISO DE
piración. mentación de poder de la máquina guardas quitadas.
q Mantenga la cabeza fuera de los antes de iniciar cualquier servicio.
PRECAUCION
humos. Utilice ventilación o
aspiración para gases.
French
q Débranchez le courant avant l’entre- q N’opérez pas avec les panneaux
q Gardez la tête à l’écart des fumées.
ED
tien. ouverts ou avec les dispositifs de
q Utilisez un ventilateur ou un aspira-
ATTENTION
protection enlevés.
teur pour ôter les fumées des zones
1 SED
de travail.
German
q Strom vor Wartungsarbeiten q Anlage nie ohne Schutzgehäuse
q Vermeiden Sie das Einatmen von
abschalten! (Netzstrom völlig öff- oder Innenschutzverkleidung in
Schweibrauch!
W ER
WARNUNG
nen; Maschine anhalten!) Betrieb setzen!
q Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
IM P
Portuguese
E SU
q Não opere com as tampas removidas. q Mantenha-se afastado das partes
q Mantenha seu rosto da fumaça.
S
q Desligue a corrente antes de fazer moventes.
q Use ventilação e exhaustão para
ATENÇÃO
serviço. q Não opere com os paineis abertos
remover fumo da zona respiratória.
q Não toque as partes elétricas nuas.
SE Y
ou guardas removidas.
NT
Japanese
RA
AR
Chinese
W
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÃTICAS DE SEGURANÇA DO EMPREGADOR.
|