Lincoln Electric Welder SVM146 A User Manual
RETURN TO MAIN INDEX  
SVM146-A  
September, 1999  
™
PRO-CUT 80  
For use with machine code numbers 10573, 10574, 10577, 10578  
Safety Depends on You  
Lincoln arc welding and cutting  
equipment is designed and built  
with safety in mind. However,  
your overall safety can be  
increased by proper installation  
. . . and thoughtful operation on  
your part. DO NOT INSTALL,  
OPERATE OR REPAIR THIS  
EQUIPMENT WITHOUT READ-  
ING THIS MANUAL AND THE  
SAFETY PRECAUTIONS CON-  
TAINED THROUGHOUT. And,  
most importantly, think before  
you act and be careful.  
SERVICE MANUAL  
• World's Leader in Welding and Cutting Products •  
• Sales and Service through Subsidiaries and Distributors Worldwide •  
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com  
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ii  
ii  
SAFETY  
ARC RAYS can burn.  
ELECTRIC SHOCK can kill.  
3.a. The electrode and work (or ground) circuits  
are electrically “hot” when the welder is on.  
Do not touch these “hot” parts with your bare  
skin or wet clothing. Wear dry, hole-free  
gloves to insulate hands.  
4.a. Use a shield with the proper filter and cover  
plates to protect your eyes from sparks and  
the rays of the arc when welding or observing  
open arc welding. Headshield and filter lens  
should conform to ANSI Z87. I standards.  
4.b. Use suitable clothing made from durable flame-resistant  
material to protect your skin and that of your helpers from  
the arc rays.  
3.b. Insulate yourself from work and ground using dry insulation.  
Make certain the insulation is large enough to cover your full  
area of physical contact with work and ground.  
4.c. Protect other nearby personnel with suitable, non-flammable  
screening and/or warn them not to watch the arc nor expose  
themselves to the arc rays or to hot spatter or metal.  
In addition to the normal safety precautions, if welding  
must be performed under electrically hazardous  
conditions (in damp locations or while wearing wet  
clothing; on metal structures such as floors, gratings or  
scaffolds; when in cramped positions such as sitting,  
kneeling or lying, if there is a high risk of unavoidable or  
accidental contact with the workpiece or ground) use  
the following equipment:  
FUMES AND GASES  
can be dangerous.  
5.a. Welding may produce fumes and gases  
hazardous to health. Avoid breathing these  
• Semiautomatic DC Constant Voltage (Wire) Welder.  
• DC Manual (Stick) Welder.  
• AC Welder with Reduced Voltage Control.  
fumes and gases.When welding, keep  
your head out of the fume. Use enough  
ventilation and/or exhaust at the arc to keep  
3.c. In semiautomatic or automatic wire welding, the electrode,  
electrode reel, welding head, nozzle or semiautomatic  
welding gun are also electrically “hot”.  
fumes and gases away from the breathing zone. When  
welding with electrodes which require special  
ventilation such as stainless or hard facing (see  
instructions on container or MSDS) or on lead or  
cadmium plated steel and other metals or coatings  
which produce highly toxic fumes, keep exposure as  
low as possible and below Threshold Limit Values (TLV)  
using local exhaust or mechanical ventilation. In  
confined spaces or in some circumstances, outdoors, a  
respirator may be required. Additional precautions are  
also required when welding on galvanized steel.  
3.d. Always be sure the work cable makes a good electrical  
connection with the metal being welded. The connection  
should be as close as possible to the area being welded.  
3.e. Ground the work or metal to be welded to a good electrical  
(earth) ground.  
3.f. Maintain the electrode holder, work clamp, welding cable and  
welding machine in good, safe operating condition. Replace  
damaged insulation.  
5.b. Do not weld in locations near chlorinated hydrocarbon vapors  
coming from degreasing, cleaning or spraying operations.  
The heat and rays of the arc can react with solvent vapors to  
form phosgene, a highly toxic gas, and other irritating  
products.  
3.g. Never dip the electrode in water for cooling.  
3.h. Never simultaneously touch electrically “hot” parts of  
electrode holders connected to two welders because voltage  
between the two can be the total of the open circuit voltage  
of both welders.  
5.c. Shielding gases used for arc welding can displace air and  
cause injury or death. Always use enough ventilation,  
especially in confined areas, to insure breathing air is safe.  
3.i. When working above floor level, use a safety belt to protect  
yourself from a fall should you get a shock.  
5.d. Read and understand the manufacturer’s instructions for this  
equipment and the consumables to be used, including the  
material safety data sheet (MSDS) and follow your  
employer’s safety practices. MSDS forms are available from  
your welding distributor or from the manufacturer.  
3.j. Also see Items 6.c. and 8.  
5.e. Also see item 1.b.  
PRO-CUT 80  
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iii  
iii  
SAFETY  
WELDING SPARKS can  
cause fire or explosion.  
CYLINDER may explode  
if damaged.  
6.a. Remove fire hazards from the welding area.  
If this is not possible, cover them to prevent  
7.a. Use only compressed gas cylinders  
containing the correct shielding gas for the  
the welding sparks from starting a fire.  
Remember that welding sparks and hot  
materials from welding can easily go through small cracks  
and openings to adjacent areas. Avoid welding near  
hydraulic lines. Have a fire extinguisher readily available.  
process used and properly operating  
regulators designed for the gas and  
pressure used. All hoses, fittings, etc. should be suitable for  
the application and maintained in good condition.  
7.b. Always keep cylinders in an upright position securely  
chained to an undercarriage or fixed support.  
6.b. Where compressed gases are to be used at the job site,  
special precautions should be used to prevent hazardous  
situations. Refer to “Safety in Welding and Cutting” (ANSI  
Standard Z49.1) and the operating information for the  
equipment being used.  
7.c. Cylinders should be located:  
•Away from areas where they may be struck or subjected to  
physical damage.  
6.c. When not welding, make certain no part of the electrode  
circuit is touching the work or ground. Accidental contact can  
cause overheating and create a fire hazard.  
•A safe distance from arc welding or cutting operations and  
any other source of heat, sparks, or flame.  
7.d. Never allow the electrode, electrode holder or any other  
electrically “hot” parts to touch a cylinder.  
6.d. Do not heat, cut or weld tanks, drums or containers until the  
proper steps have been taken to insure that such procedures  
will not cause flammable or toxic vapors from substances  
inside. They can cause an explosion even though they have  
been “cleaned”. For information, purchase “Recommended  
Safe Practices for the Preparation for Welding and Cutting of  
Containers and Piping That Have Held Hazardous  
Substances”, AWS F4.1 from the American Welding Society  
(see address above).  
7.e. Keep your head and face away from the cylinder valve outlet  
when opening the cylinder valve.  
7.f. Valve protection caps should always be in place and hand  
tight except when the cylinder is in use or connected for  
use.  
7.g. Read and follow the instructions on compressed gas  
cylinders, associated equipment, and CGA publication P-l,  
“Precautions for Safe Handling of Compressed Gases in  
Cylinders,” available from the Compressed Gas Association  
1235 Jefferson Davis Highway, Arlington, VA 22202.  
6.e. Vent hollow castings or containers before heating, cutting or  
welding. They may explode.  
6.f. Sparks and spatter are thrown from the welding arc. Wear oil  
free protective garments such as leather gloves, heavy shirt,  
cuffless trousers, high shoes and a cap over your hair. Wear  
ear plugs when welding out of position or in confined places.  
Always wear safety glasses with side shields when in a  
welding area.  
FOR ELECTRICALLY  
powered equipment.  
6.g. Connect the work cable to the work as close to the welding  
area as practical. Work cables connected to the building  
framework or other locations away from the welding area  
increase the possibility of the welding current passing  
through lifting chains, crane cables or other alternate circuits.  
This can create fire hazards or overheat lifting chains or  
cables until they fail.  
8.a. Turn off input power using the disconnect  
switch at the fuse box before working on  
the equipment.  
8.b. Install equipment in accordance with the U.S. National  
Electrical Code, all local codes and the manufacturer’s  
recommendations.  
6.h. Also see item 1.c.  
8.c. Ground the equipment in accordance with the U.S. National  
Electrical Code and the manufacturer’s recommendations.  
PRO-CUT 80  
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iv  
iv  
SAFETY  
7. Quand on ne soude pas, poser la pince à une endroit isolé  
PRÉCAUTIONS DE SÛRETÉ  
de la masse. Un court-circuit accidental peut provoquer un  
échauffement et un risque d’incendie.  
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:  
8. S’assurer que la masse est connectée le plus prés possible  
de la zone de travail qu’il est pratique de la faire. Si on place  
la masse sur la charpente de la construction ou d’autres  
endroits éloignés de la zone de travail, on augmente le  
risque de voir passer le courant de soudage par les chaines  
de levage, câbles de grue, ou atres circuits. Cela peut  
provoquer des risques d’incendie ou d’echauffement des  
chaines et des câbles jusqu’à ce qu’ils se rompent.  
Sûreté Pour Soudage A L’Arc  
1. Protegez-vous contre la secousse électrique:  
a. Les circuits à l’électrode et à la piéce sont sous tension  
quand la machine à souder est en marche. Eviter tou-  
jours tout contact entre les parties sous tension et la  
peau nue ou les vétements mouillés. Porter des gants  
secs et sans trous pour isoler les mains.  
9. Assurer une ventilation suffisante dans la zone de soudage.  
Ceci est particuliérement important pour le soudage de tôles  
galvanisées plombées, ou cadmiées ou tout autre métal qui  
produit des fumées toxiques.  
b. Faire trés attention de bien s’isoler de la masse quand  
on soude dans des endroits humides, ou sur un planch-  
er metallique ou des grilles metalliques, principalement  
dans les positions assis ou couché pour lesquelles une  
grande partie du corps peut être en contact avec la  
masse.  
10. Ne pas souder en présence de vapeurs de chlore provenant  
d’opéerations de dégraissage, nettoyage ou pistolage. La  
chaleur ou les rayons de l’arc peuvent réagir avec les  
vapeurs du solvant pour produire du phosgéne (gas forte-  
ment roxique) ou autres produits irritants.  
c. Maintenir le porte-électrode, la pince de masse, le câble  
de soudage et la machine à souder en bon et sûr état  
defonctionnement.  
PRÉCAUTIONS DE SÛRETÉ POUR LES  
MACHINES À SOUDER À TRANSFOR-  
MATEUR ET À REDRESSEUR  
d. Ne jamais plonger le porte-électrode dans l’eau pour le  
refroidir.  
e. Ne jamais toucher simultanément les parties sous ten-  
sion des porte-électrodes connectés à deux machines à  
souder parce que la tension entre les deux pinces peut  
être le total de la tension à vide des deux machines.  
1. Relier à la terre le chassis du poste conformement au code  
de l’électricité et aux recommendations du fabricant. Le dis-  
positif de montage ou la piece à souder doit être branché à  
une bonne mise à la terre.  
2. Dans le cas de travail au dessus du niveau du sol, se protéger  
contre les chutes dans le cas ou on recoit un choc. Ne jamais  
enroule le câble-électrode autour de n’importe quelle partie  
du corps.  
2. Autant que possible, l’installation et l’entretien du poste  
seront effectués par un électricien qualifié.  
3. Avant de faires des travaux à l’interieur de poste, la  
debrancher à l’interrupteur à la boite de fusibles.  
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,  
donc:  
4. Garder tous les couvercles et dispostifis de sûreté à leur  
place.  
a. Utiliser un bon masque avec un verre filtrant approprié  
ainsi qu’un verre blanc afin de se protéger les yeux du  
rayonnement de l’arc et des projections quand on soude  
ou quand on regarde l’arc.  
b. Porter des vêtements convenables afin de protéger la  
peau de soudeur et des aides contre le rayonnementde  
l’arc.  
c. Protéger l’autre personnel travaillant à proximité au  
soudage à l’aide d’écrans appropriés et non-inflamma-  
bles.  
4. Des gouttes de laiter en fusion sont émises de l’arc de  
soudage. Se protéger avec es vêtements de protection libres  
de l’huile, tels que les gants en cuir, chemise épaisse, pan-  
talons sans revers, et chaussures montantes.  
5. Toujours porter des lunettes de sécurité dans la zone de  
soudage. Utiliser des lunettes avec écrans lateraux dans les  
zones où l’on pique le laitier.  
6. Eloigner les matériaux inflammables ou les recouvrir afin de  
prévenir ttout risque d’incendie dû étincelles.  
PRO-CUT 80  
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v
v
MASTER TABLE OF CONTENTS FOR ALL SECTIONS  
RETURN TO MAIN INDEX  
Page  
Safety.................................................................................................................................................i-iv  
Installation.............................................................................................................................Section A  
Technical Specifications ..........................................................................................................A-2/3  
Safety Precautions......................................................................................................................A-4  
Select Suitable Location.............................................................................................................A-4  
Stacking ......................................................................................................................................A-4  
Lifting and Moving ......................................................................................................................A-4  
Tilting...........................................................................................................................................A-4  
High Frequency Interference Protection.....................................................................................A-4  
Input Electrical Connections.......................................................................................................A-5  
Input Power Cord Connector Installation ...................................................................................A-5  
Frame Grounding........................................................................................................................A-5  
Gas Input Connections...............................................................................................................A-7  
Output Connections....................................................................................................................A-8  
Operation...............................................................................................................................Section B  
Safety Precautions......................................................................................................................B-2  
General Description....................................................................................................................B-3  
Recommended Processes and Equipment................................................................................B-3  
Operational Features and Controls ............................................................................................B-3  
Design Features and Advantages ..............................................................................................B-3  
Cutting Capability.......................................................................................................................B-4  
Consumable Life.........................................................................................................................B-4  
Limitations ..................................................................................................................................B-4  
Controls and Settings.................................................................................................................B-5  
Pilot Arc Discussion....................................................................................................................B-5  
Cutting Operation .......................................................................................................................B-5  
User Responsibility.....................................................................................................................B-7  
Preheat Temperature for Plasma Cutting ...................................................................................B-7  
Procedure Recommendations....................................................................................................B-7  
Accessories...........................................................................................................................Section C  
Maintenance .........................................................................................................................Section D  
Theory of Operation .............................................................................................................Section E  
Troubleshooting and Repair.................................................................................................Section F  
Safety Precautions......................................................................................................................F-2  
How to Use Troubleshooting Guide............................................................................................F-2  
Troubleshooting Guide................................................................................................................F-4  
Test Procedures ........................................................................................................................F-10  
Replacement Procedures .........................................................................................................F-40  
Electrical Diagrams..............................................................................................................Section G  
Parts Manual....................................................................................................................P-340 Series  
PRO-CUT 80  
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Section A-1  
Section A-1  
TABLE OF CONTENTS  
- INSTALLATION SECTION -  
Installation  
Technical Specifications .............................................................................................................A-2  
Safety Precautions......................................................................................................................A-4  
Select Suitable Location.............................................................................................................A-4  
Stacking......................................................................................................................................A-4  
Lifting and Moving......................................................................................................................A-4  
Tilting ..........................................................................................................................................A-4  
High Frequency Interference Protection.....................................................................................A-4  
Input Electrical Connections.......................................................................................................A-5  
Ground Connection..............................................................................................................A-5  
Input Power Cord Connector Installation...................................................................................A-5  
Input Wire and Fuse Size .....................................................................................................A-5  
Reconnect Procedure...........................................................................................................A-6  
Gas Input Connections...............................................................................................................A-7  
Output Connections ...................................................................................................................A-8  
Torch Connection .................................................................................................................A-8  
PRO-CUT 80  
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A-2  
A-2  
INSTALLATION  
TECHNICAL SPECIFICATIONS - PRO-CUT 80  
INPUT RATINGS  
Single Phase Input  
Voltage and Hertz  
Input Currents  
Rated Output Amps  
208/1/60  
230/1/60  
460/1/60  
87  
81  
48  
80  
80  
80  
Three Phase Input  
Voltage and Hertz  
Input Currents  
Rated Output Amps  
208/3/60  
230/3/60  
460/3/60  
48  
44  
25  
80  
80  
80  
IDLE CURRENT AND WATTS  
IDLE CURRENT AND WATTS  
230/1/60  
0.61 Amps  
140 Watts  
RATED OUTPUT  
Duty Cycle  
60%  
Rated Output Amps  
80  
60  
100%  
OUTPUT  
Current Range  
Open Circuit Voltage  
Pilot Current  
35 - 85 Amps  
335VDC Maximum  
20 Amps @ 100%  
Duty Cycle  
PRO-CUT 80  
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A-3  
A-3  
INSTALLATION  
TECHNICAL SPECIFICATIONS (Cont’d) - PRO-CUT 80  
GAS REQUIREMENTS  
Required Gas Flow Rate  
Required Gas Inlet Pressure  
70 PSI @ 480 SCHF  
80 to 150 PSI  
(4.8 Bar. @ 13550 LHR)  
(5.4 Bar. to 10.2 Bar.)  
RECOMMENDED INPUT WIRE AND FUSE SIZES  
For all plasma cutting applications based on U.S. National Electrical Code  
Ambient Temperature 30°C or Less  
AC Input Voltage  
Fuse (Super Lag)  
Circuit Breaker  
(Delay Type)  
Type 75°C  
Copper Wire in Conduit AWG  
(IEC) Sizes  
at  
60 Hertz  
230VAC Single Phase  
460VAC Single Phase  
100 Amps  
60 Amps  
#4 (21.1mm2)  
#4 (21.1mm2)  
#8 (8.4mm2)  
#8 (8.4mm2)  
230VAC Three Phase  
460VAC Three Phase  
60 Amps  
40 Amps  
#8 (8.4mm2)  
#8 (8.4mm2)  
#10 (5.3mm2)  
#10 (5.3mm2)  
PHYSICAL DIMENSIONS  
Height  
Width  
Depth  
Weight with  
Torch Cable  
16.5 Inches  
419 mm  
13.75 Inches  
349 mm  
29.5 Inches  
749 mm  
98 lbs. (44.5 kg.)  
(25 ft. cable)  
113 lbs. (51.4 kg.)  
(50 ft. cable)  
PRO-CUT 80  
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A-4  
A-4  
INSTALLATION  
Read this entire installation section before you  
start installation.  
LIFTING AND MOVING  
WARNING  
SAFETY PRECAUTIONS  
FALLING EQUIPMENT can cause  
injury.  
WARNING  
• Do not use the pull handle on the  
optional undercarriage, if installed,  
to lift the machine. This handle is  
not designed to support the full  
weight of the machine. Using it to  
lift the machine could cause per-  
sonal injury or damage to the  
machine.  
ELECTRIC SHOCK can kill.  
• Turn the input power OFF at the  
disconnect switch or fuse box  
and discharge input capacitors  
before working inside the equip-  
ment.  
• Do not touch electrically hot parts or electrodes with  
your skin or wet clothing.  
• Either the front or rear handles or both may be used  
to lift or move the machine.  
• Always connect the 80 grounding terminal (located  
on the side of the Case Back Assembly) to a good  
electrical earth ground.  
TILTING  
• Always wear dry, insulating gloves.  
The PRO-CUT 80 must be placed on a stable, level  
surface so it will not topple over.  
• Turn the 80 Power Switch OFF when connecting  
power cord to input power.  
HIGH FREQUENCY INTERFERENCE  
PROTECTION  
Only qualified personnel should install, use, or ser-  
vice this equipment.  
The PRO-CUT 80 employs a touch start mechanism  
for arc initiation. This eliminates high frequency emis-  
sions from the machine as compared with spark gap  
and solid state type high frequency generators. Keep  
in mind, though, that these machines may be used in  
an environment where other high frequency generating  
machines are operating. By taking the following steps,  
you can minimize high frequency interference.  
SELECT SUITABLE LOCATION  
Place the PRO-CUT 80 where clean cool air can freely  
circulate in through the rear louvers and out through  
the front/bottom opening. Dirt, dust or any foreign  
material that can be drawn into the machine should be  
kept at a minimum. Failure to observe these precau-  
tions can result in excessive operating temperatures  
and nuisance shutdown of the machine.  
• Make sure the power supply chassis is connected to  
a good earth ground. The work terminal ground does  
NOT ground the machine frame.  
• Keep the work ground clamp isolated from other work  
clamps that have high frequency.  
A source of clean, dry air or nitrogen must be supplied  
to the PRO-CUT 80. Oil in the air is a severe problem  
and must be avoided. The supply pressure must be  
between 80 and 150 psi. The flow rate is approximate-  
ly 6.0 cfm (170 l/min.). Failure to observe these pre-  
cautions could result in excessive operating tempera-  
tures or damage to the torch.  
• If the ground clamp cannot be isolated, then keep the  
clamp as far as possible from other work clamp con-  
nections.  
• When the machine is enclosed in a metal building,  
several good earth driven electrical grounds around  
the periphery of the building are recommended.  
Failure to observe these recommended installation pro-  
cedures may cause improper function of the Pro-Cut or  
possibly even damage the control system or power  
supply components.  
STACKING  
The PRO-CUT 80 cannot be stacked.  
PRO-CUT 80  
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A-5  
A-5  
INSTALLATION  
GROUND CONNECTION  
INPUT CONNECTIONS  
The frame of the PRO-CUT 80 must be properly grounded.  
A ground terminal marked with the symbol is  
WARNING  
mounted on the case bottom directly behind the input  
power switch for this purpose. The ground lead of the  
input power cord that is attached to the machine must  
be connected to this ground terminal. See the  
National Electric Code for details on proper grounding  
methods. Install in accordance with all local and  
national electrical codes.  
ELECTRIC SHOCK can kill.  
• Have a qualified electrician install and  
service this equipment.  
• Turn the input power off at the fuse box  
before working on this equipment.  
• Do not touch electrically hot parts.  
INPUT POWER CORD CONNECTOR  
INSTALLATION  
Before installing the machine, check that input supply  
voltage, phase, and frequency are the same as the  
machine’s voltage, phase, and frequency as specified  
on the machine’s rating plate. See Figure A.1.  
The PRO-CUT 80 is supplied with one 11 foot (3.35m)  
#8 AWG 3 lead input power cord already connected to  
the machine. A cord connector provides a strain relief  
for the input power cord as it passes through the left  
rear access hole. The cord connector is designed for  
a cord diameter of .40 - 1.03 in (10.2 - 26.2mm) if it  
becomes necessary to install a different input cord.  
See Figure A.1.  
FIGURE A.1 – RATING PLATE LOCATION  
For three phase connection: Replace the input power  
cord with a #10 AWG 4 lead cable.  
1
Connect the leads of the cable to a fused power panel.  
Make sure the green lead is connected to the panel  
and the panel is connected to a good earth ground.  
Install in accordance with all local and national electric  
codes.  
INPUT WIRE AND FUSE SIZE  
Fuse the input circuit with the super lag fuses or delay  
type circuit breakers recommended on the Technical  
Specifications page. Choose an input and grounding  
wire size according to local or national codes; also see  
the Technical Specifications page. Using fuses or  
circuit breakers smaller than recommended may result  
in “nuisance” shut-offs from inrush currents, even if  
you are not cutting at high currents.  
2
3
1. CASE BACK  
2. RATING PLATE  
3. POWER CORD CONNECTOR WITH STRAIN RELIEF  
The PRO-CUT 80 should be connected only by a qual-  
ified electrician. Installation should be made in accor-  
dance with the U.S. National Electrical Code, all local  
codes, and the information detailed below.  
PRO-CUT 80  
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A-6  
A-6  
INSTALLATION  
FIGURE A.2 – RECONNECTION DIAGRAM  
RECONNECT PROCEDURE  
When received directly from the factory, the machines  
are internally connected for 230 VAC. Reconnection  
will be necessary if a higher input voltage is used. To  
reconnect the Pro-Cut to 460 VAC or to connect back  
to 230 VAC, follow the directions as outlined below.  
Follow this procedure ONLY while the Pro-Cut is dis-  
connected from the input power.  
RECONNECT PROCEDURE  
WARNING  
• Disconnect input power before  
inspecting or servicing machine.  
• Do not operate with wraparound  
removed.  
• Do not touch electrically live parts.  
ELECTRIC  
CAUTION  
SHOCK  
• Only qualified persons should install,  
use, or service this equipment.  
CAN KILL  
Failure to follow these instructions can cause immedi-  
ate failure of components in the welder.  
1. BE SURE POWER SWITCH IS OFF.  
2. CONNECT LEAD 'A' TO DESIRED INPUT VOLTAGE RANGE.  
440 - 460V  
380 - 415V  
1. Open the access door on the side of the machine.  
Connection instructions are also included on the  
inside of the door.  
'A'  
220 - 230V  
200 - 208V  
2. For 230: Position the large switch to 200-230. See  
Figure A.2.  
3. POSITION SWITCH TO DESIRED INPUT VOLTAGE RANGE.  
For 460: Position the large switch to 380-460. See  
Figure A-2.  
VOLTAGE = 380 - 460V  
3. Move the “A” lead to the appropriate terminal.  
VOLTAGE = 200 - 230V  
PRO-CUT 80  
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A-7  
A-7  
INSTALLATION  
FIGURE A.3 - COMPRESSED GAS CONNECTION  
GAS INPUT CONNECTIONS  
Supply the PRO-CUT 80 with clean compressed air or  
nitrogen.  
• Supply pressure must be between 80 psi and 150  
psi.  
1
• Flow rate should be approximately 6.0 cfm (170  
I/min.).  
NOTE: Oil in the air supply to the PRO-CUT 80 can  
cause severe problems. Use only a clean air  
supply.  
2
• Connect the gas supply to the PRO-CUT 80’s  
pneumatic nipple at the air filter. See Figure A.3.  
3
• Compressed gas should be supplied to the fitting  
connection mounted on the filter at the rear of the  
machine. If necessary, this fitting can be removed  
allowing plumbing access through the 1/4 in.  
(6.4mm) NPT input port on the filter body.  
4
WARNING  
CYLINDER could explode if damaged.  
• Keep cylinder upright and chained to a fixed support.  
1. CASE BACK  
2. PNEUMATIC NIPPLE  
3. AIR FILTER  
• Keep cylinder away from areas  
where it could be damaged.  
4. FLEX TUBE (TO REGULATOR INSIDE MACHINE)  
• Never lift machine with cylinder  
attached.  
• Never allow the cutting torch to  
touch the cylinder.  
• Keep cylinder away from live elec-  
trical parts.  
• Maximum inlet pressure 150 psi.  
NOTE: When using nitrogen gas from a cylinder, the  
cylinder must have a pressure regulator.  
• Maximum psi from nitrogen gas cylinder to PRO-  
CUT 80 regulator should never exceed 150 psi.  
• Install a hose between the nitrogen gas cylinder  
regulator and the PRO-CUT 80 gas inlet.  
PRO-CUT 80  
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A-8  
A-8  
INSTALLATION  
FIGURE A.4 - TORCH CONNECTION  
OUTPUT CONNECTIONS  
AT CASE FRONT  
Gas  
TORCH CONNECTION  
Reset  
Button  
Purge  
Button  
Gas  
Regulator  
Gauge  
Status  
Indicators  
The PRO-CUT 80 is supplied from the factory with a  
PCT 80 cutting torch. Additional cutting torches can  
be ordered from the K1571 series. Hand-held and  
mechanized torches come with 25 or 50 foot cables.  
XXXX XXXX XXXX XXXX  
Gas  
Regulator  
Knob  
Output  
Control  
Knob  
All torches are connected to the Pro-Cut with a quick  
connect at the case front for easy change over. See  
Figure A-4.  
PRO-CUT 80  
Consumable  
Storage  
(behind  
door)  
For more information on the torch and its components,  
refer to the PCT 80 Operator’s Manual (IM595).  
Input  
Power  
Switch  
Torch  
Connector  
Work  
Cable  
Interface  
Connector  
PRO-CUT 80  
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Section B-1  
Section B-1  
TABLE OF CONTENTS  
- OPERATION SECTION -  
Operation...............................................................................................................................Section B  
Safety Instructions......................................................................................................................B-2  
General Description....................................................................................................................B-3  
Recommended Process and Equipment....................................................................................B-3  
Operational Features and Controls ............................................................................................B-3  
Design Features and Advantages...............................................................................................B-3  
Cutting Capability .......................................................................................................................B-4  
Consumable Life.........................................................................................................................B-4  
Limitations...................................................................................................................................B-4  
Controls and Settings.................................................................................................................B-5  
Pilot Arc Considerations.............................................................................................................B-5  
Cutting Operation .......................................................................................................................B-5  
Safety Status Indicator ..............................................................................................................B-6  
User Responsibility.....................................................................................................................B-7  
Preheat Temperature for Plasma Cutting ...................................................................................B-7  
Procedure Recommendations....................................................................................................B-7  
General.................................................................................................................................B-7  
Thin Gauge Sheet Metal ......................................................................................................B-7  
Thick Sections of Metal........................................................................................................B-8  
Suggestions for Extra Utility From the Pro-Cut System......................................................B-8  
Machine Interface........................................................................................................................B-9  
Arc Start.......................................................................................................................................B-9  
Arc Initiated.................................................................................................................................B-9  
Arc Voltage..................................................................................................................................B-9  
PRO-CUT 80  
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B-2  
B-2  
OPERATION  
OPERATING INSTRUCTIONS  
Read and understand this entire section of operating  
instructions before operating the machine.  
SAFETY INSTRUCTIONS  
WARNING  
ELECTRIC SHOCK can kill.  
• Do not touch electrically live parts or  
electrodes with your skin or wet cloth-  
ing.  
• Insulate yourself from the work and ground.  
• Always wear dry, insulating gloves.  
FUMES AND GASES can be  
dangerous.  
• Keep your head out of fumes.  
• Use ventilation or exhaust to remove fumes from  
breathing zone.  
CUTTING SPARKS can cause  
fire or explosion.  
• Keep flammable material away.  
• Do not cut containers that have held combustibles.  
ARC RAYS can burn.  
• Wear eye, ear, and body protection.  
PLASMA ARC can injure.  
• Keep your body away from nozzle and  
plasma arc.  
• Operate the pilot arc with caution. The  
pilot arc is capable of burning the oper-  
ator, others, or even piercing safety  
clothing.  
Observe additional Safety Guidelines detailed in  
the beginning of this manual.  
PRO-CUT 80  
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B-3  
B-3  
OPERATION  
GENERAL DESCRIPTION  
DESIGN FEATURES AND  
ADVANTAGES  
The PRO-CUT 80 is an inverter based constant cur-  
rent, continuous control plasma cutting power source.  
It provides superior and reliable starting characteris-  
tics, cutting visibility and arc stability. When cutting  
expanded metal, the PRO-CUT 80 out-performs the  
competition due to its quick, clean response to arc  
transfers. The power supply design provides high  
transfer-to-cut distances, which makes pierce cutting  
more reliable with less nozzle wear. The control system  
has a safety mechanism to insure that the nozzle and  
electrode are in place before cutting or gouging. This  
is extremely important due to the high voltages  
involved.  
The microprocessor controlled PRO-CUT 80 design  
makes plasma cutting and gouging tasks uncompli-  
cated. This list of design features and advantages will  
help you understand the machine's total capabilities  
so that you can get maximum use from your machine.  
• Light weight and portable design for industrial use.  
• Continuous control, 35 - 85 amps.  
• Reliable touch start mechanism for plasma arc initi-  
ation.  
• Unique microprocessor controlled starting  
sequence for safe and consistent starting.  
The PRO-CUT 80 comes standard with an air regula-  
tor, coarse air filter, and pressure gauge. There are six  
different torch and cable systems to choose from:  
hand-held torch with 25’ or 50’ cable, machine and  
robotic torch both with 25’ and 50’ cable.  
Consumables are included so that cutting can begin  
right out of the box. Consumables can also be  
ordered as individual packages.  
• Rapid arc transfer for fast cutting of expanded  
metal.  
• High transfer distance for ease of use.  
• Input overvoltage protection.  
• 3.0 second pilot arc.  
• Purge momentary push button.  
The PRO-CUT 80 initiates the plasma arc with a sim-  
ple, yet reliable, touch-start mechanism. This system  
eliminates many of the failure problems associated  
with hi-frequency start systems. The PRO-CUT 80 is  
capable of cutting with nitrogen or air.  
• Air regulator and pressure gauge located on the  
front of machine for convenience.  
• ”Parts-in-Place” mechanism to detect proper instal-  
lation of consumables and torch.  
The PRO-CUT 80 is controlled by a microprocessor-  
based control board. The machine performs rudimen-  
tary self troubleshooting when powered up, which aids  
in field servicing.  
• Automatic detection of faulty output control.  
• In-line coarse air filter.  
• Preflow/Postflow timing. Preflow is eliminated if arc  
is re-initiated in Postflow.  
RECOMMENDED PROCESSES AND  
EQUIPMENT  
• Thermostatic Protection.  
• Solid state overcurrent protection.  
The PRO-CUT 80 is capable of all cutting and gouging  
applications within its output capacity of 35 to 85  
amps. These applications include thin gage sheet  
metal and expanded metal.  
• Works with pure nitrogen for cutting nonferrous  
materials.  
• Reconnectable for multiple input voltages.  
• Quick disconnect torch.  
• Display indicators for machine status.  
OPERATIONAL FEATURES AND  
CONTROLS  
• Unique electrode and Vortech™ nozzle design for  
optimum cooling and long life.  
The PRO-CUT 80 comes with an ON/OFF POWER  
SWITCH, OUTPUT CURRENT CONTROL, PURGE  
BUTTON, STATUS INDICATORS and a SAFETY  
RESET BUTTON. See Figure B.2 and related discus-  
sion.  
• Swirl texture inside Vortech™ nozzle for better start-  
ing reliability and higher quality cuts.  
• Unique drag cup design for durability and elimina-  
tion of double arcing.  
PRO-CUT 80  
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B-4  
B-4  
OPERATION  
CUTTING CAPABILITY  
The PRO-CUT 80 is rated at 80 amps, at 60% duty  
cycle on a 10 minute basis or 60 amps, at 100% duty  
cycle. If the duty cycle is exceeded, a thermal protec-  
tor will shut off the output of the machine until it cools  
to the normal operating temperature.  
Figure B.1 shows the cut capacity of the PRO-CUT 80  
when cutting mild steel. The graph plots cut thickness  
vs. torch travel speed with a torch standoff of 0.15 in.  
(3.8mm).  
Example: 0.5 material  
Amps  
Speed (IPM)  
55  
80  
25  
35  
FIGURE B.1 – LINCOLN’S PRO-CUT 80 MILD STEEL CUT CAPACITY CHART  
Lincoln's PRO-CUT 80  
Mild Steel Cut Capacity Chart  
100  
80  
60  
40  
20  
25 A  
55 A  
0.750  
80 A  
1.00  
35 A  
0.500  
0
0.000  
0.125  
0.250  
Material Thickness  
0.375  
0.625  
CONSUMABLE LIFE  
LIMITATIONS  
The expected life for the PRO-CUT 80's electrode  
under normal operating conditions is approximately  
160 starts/cuts. An erosion of .060 in. (1.5mm) is typ-  
ical for end of electrode life. However, the electrode  
may last longer. A green and erratic arc will indicate  
definite electrode failure, and the electrode should be  
replaced immediately.  
Do not exceed output current and duty cycle rating of  
machine. Do not use the PRO-CUT 80 for pipe thaw-  
ing.  
It is recommended that consumables be replaced in  
complete sets. (Example: Electrode and Nozzle). This  
will maximize the performance of the PRO-CUT 80  
system.  
PRO-CUT 80  
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B-5  
B-5  
OPERATION  
Occasionally, the pilot arc may sputter or start inter-  
mittently. This is aggravated when the consumables  
are worn or the air pressure is too high. Always keep  
in mind that the pilot arc is designed to transfer the arc  
to the workpiece and not for numerous starts without  
cutting.  
CONTROLS AND SETTINGS  
FIGURE B.2 - CASE FRONT CONTROLS  
Gas  
Reset  
Button  
Purge  
Button  
Gas  
Regulator  
Gauge  
Status  
Indicators  
When the pilot arc is started, a slight impulse will be  
felt in the torch handle. This occurrence is normal and  
is the mechanism which starts the plasma arc. This  
impulse can also be used to help troubleshoot a "no  
start" condition.  
XXXX XXXX XXXX XXXX  
Gas  
Regulator  
Knob  
Output  
Control  
Knob  
PRO-CUT 80  
Consumable  
Storage  
(behind  
door)  
CUTTING OPERATION  
When preparing to cut or gouge, position the machine  
as close to the work as possible. Make sure you have  
all materials needed to complete the job and have  
taken all safety precautions. It is important to follow  
these operating steps each time you use the machine.  
Input  
Power  
Switch  
Torch  
Connector  
Work  
Cable  
Interface  
Connector  
• Turn the machine's ON/OFF POWER SWITCH to  
the OFF position.  
OUTPUT CURRENT CONTROL KNOB - Adjusts the  
amount of cutting current applied. Affects cutting  
speed, dross formation, cut width, heat zone and trav-  
el speed.  
• Connect the air supply to the machine.  
• Turn the main power and the machine power switch  
on.  
TORCH CONNECTOR - Quick- connect type coupling  
for the PCT 80 cutting torch.  
- The fan should start.  
- The pre-charge circuit will operate for 3 seconds,  
then the green "Power" status indicator should  
turn on.  
- If the "SAFETY" status indicator is lit, push the  
"Reset" button. If there is no problem, the status  
indicator will go off. If there is a problem, refer to  
"STATUS INDICATOR" in this section.  
WORK CABLE - Provides clamp and cable connection  
to workpiece.  
ON/OFF POWER SWITCH - Turns machine on or off.  
GAS REGULATOR KNOB - Adjusts compressed gas  
pressure delivered to the torch. Length of torch hose  
is an adjustment factor. Optimum setting is 70-75 psi.  
The gas purge button must be pressed in to set pres-  
sure.  
• Be sure that the work lead is clamped to the work-  
piece before cutting.  
• Set the output current control knob for maximum  
current for high cutting speed and less dross forma-  
tion per Figure B.1. Reduce the current, if desired,  
to reduce the kerf (cut) width, heat affected zone or  
travel speed as required.  
GAS REGULATOR GUAGE - Provides gas presssure  
reading as set by the gas regulator knob.  
GAS PURGE BUTTON - Used to check or set gas  
pressure. Push in and hold to check pressure, then  
continue to hold to set the pressure. Shuts off gas  
when released.  
• Push-in and hold the Purge button to check or set  
the gas pressure. Pull the pressure regulator cap out  
and turn it to set the pressure.  
RESET BUTTON - Used to reset the machine following  
a safety circuit trip.  
- Adjust the gas regulator for 70 PSI for 25 foot  
(7.62m) torches or 75 PSI for 50 foot (15.24m)  
torches.  
STATUS (DISPLAY) BOARD INDICATORS - Four lights  
indicating Power, Gas Low, Thermal and Safety.  
- Release the Purge button.  
PILOT ARC CONSIDERATIONS  
The Pro-Cut has a smooth, continuous pilot arc. The  
pilot arc is only a means of transferring the arc to the  
workpiece for cutting. Repeated pilot arc starts, in  
rapid succession, is not recommended as these starts  
will  
generally  
reduce  
consumable  
life.  
PRO-CUT 80  
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B-6  
B-6  
OPERATION  
5° - 15° Leading Angle  
- The gas will immediately turn off. The pressure  
gauge may show an increase in pressure after the air  
turns off, but this is normal. Do NOT reset the pres-  
sure while the air is NOT flowing.  
• When ready to cut, place the torch near the work,  
make certain all safety precautions have been taken  
and pull the trigger.  
Direction of Travel  
- The air will flow for a preflow time of 2 seconds  
and the pilot arc will start. (This is true unless the  
machine is in postflow, then the preflow time is  
skipped and the pilot arc will start immediately.)  
- The pilot arc will run for 3 seconds and shut off  
unless the arc is brought in contact with the work  
and the arc is transferred. Avoid excessive pilot  
arc time by transferring the arc to the workpiece  
quickly to improve parts life.  
10° - 20°  
Arc Lag  
• Finish the cut to be made and release the trigger.  
• When the trigger is released, the arc will stop.  
- When the arc is brought within 1/4 in. (6.4mm)  
from the workpiece the arc will transfer, the cur-  
rent will ramp up to the setting on the control  
panel, and the cut can last indefinitely (or until the  
duty cycle of the Pro-Cut is exceeded). Do not  
touch the nozzle to the work when cutting.  
Damage to the consumables may result.  
- The gas will continue to flow for 10 seconds of  
postflow. If the trigger is activated within this time  
period, the pilot arc will immediately restart.  
• If the dross is difficult to remove, reduce the cutting  
speed. High speed dross is more difficult to remove  
than low speed dross.  
• Pierce the workpiece by slowly lowering the torch  
onto the metal at a 30° angle away from the opera-  
tor. This will blow the dross away from the torch tip.  
Slowly rotate the torch to vertical position as the arc  
becomes deeper.  
• The right side of the cut is more square than the left  
as viewed along the direction of travel.  
• Clean spatter and scale from the nozzle and drag  
cup frequently.  
• For gouging, tilt the torch about 45° from the work-  
piece and hold the nozzle 1/8 in. (3.2mm) to 3/16”  
(4.7mm) above the workpiece.  
TORCH AT 300 ANGLE  
TO PIERCE  
ANGLE  
OF APPROACH  
ROTATE TO  
900 ANGLE TO CUT  
300  
900  
VERTICAL ANGLE  
FOR CUTTING  
TORCH HELD AT  
450 ANGLE  
THROUGHOUT GOUGE  
CUT  
ANGLE  
MAINTAINED  
THROUGHOUT  
GOUGE  
• Hold the nozzle standoff 1/8 in. (3.2mm) to 3/16 in.  
(4.7mm) above the workpiece during cutting. Do not  
let the torch nozzle touch the work or carry a long  
arc.  
• Keep moving while cutting. Cut at a steady speed  
without pausing. Maintain the cutting speed so that  
the arc lag is 10° to 20° behind the travel direction.  
SAFETY STATUS INDICATOR  
• If the "SAFETY" status indicators light at any time,  
check the following:  
•
Use a 5° - 15° leading angle in the direction of the cut.  
- Check the assembly of the torch consumables. If  
they are not properly in place, the machine will not  
start. Make sure that the shield cup is hand  
tight. Do not use pliers or overtighten.  
• Use the drag cup to maintain constant standoff for  
better cut quality and to protect the nozzle from  
spatter.  
• Use the drag cup with a metal template to prevent  
nozzle double arcing.  
PRO-CUT 80  
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B-7  
B-7  
OPERATION  
PREHEAT TEMPERATURE FOR  
PLASMA CUTTING  
WARNING  
ELECTRIC SHOCK can kill.  
Preheat temperature control is not necessary in most  
applications when plasma arc cutting or gouging.  
Preheat temperature control may be necessary on  
high carbon alloy steels and heat treated aluminum for  
crack resistance and hardness control. Job condi-  
tions, prevailing codes, alloy level, and other consider-  
ations may also require preheat temperature control.  
The recommended minimum preheat temperature for  
plate thickness up to 1/2 in. (12.7mm) is 70°F (21.1°C).  
Higher temperatures may be used as required by the  
job conditions and/or prevailing codes. If cracking or  
excessive hardness occurs on the cut face, higher pre-  
heat temperature may be required.  
• Turn off machine at the discon-  
nect switch on the front of the  
machine before tightening,  
cleaning or replacing consum-  
ables.  
- Check the conditions of the inside of the nozzle. If  
debris has collected, rub the electrode on the  
inside bottom of the nozzle to remove any oxide  
layer that may have built up. Refer to  
“Suggestions for Extra Utility from the Pro-Cut  
System.”  
-
Check the condition of the electrode. If the end has  
a crater-like appearance, replace it along with the  
nozzle. The maximum wear depth of the electrode  
is approximately .062 in. (1.6mm). A green and  
erratic arc will indicate definite electrode failure.  
The electrode should be replaced immediately.  
PROCEDURE RECOMMENDATIONS  
When properly used, plasma arc cutting or gouging is  
a very economical process. Improper use will result in  
a very high operating cost.  
• Replace the nozzle when the orifice exit is eroded  
away or oval shaped.  
GENERAL - IN ALL CASES  
• Follow safety precautions as printed throughout this  
manual and on the machine.  
• After the problem is found, or if there is nothing  
apparently wrong, reset the machine by pressing  
the "Reset" button. (It is possible for electrical noise  
to trip the safety circuit on rare occasions. This  
should not be a regular occurrence.)  
THIN GAUGE SHEET METAL  
• If the machine does not reset or continues to trip,  
consult the Troubleshooting Section.  
Torch Standoff  
Machine Output Setting  
• Use the proper cutting or gouging procedures  
referred to in “Procedure Recommendations”  
below.  
45  
USER RESPONSIBILITY  
Because design, fabrication, erection, and cutting vari-  
ables affect results, the serviceability of a product or  
structure is the responsibility of the user. Variation  
such as plate chemistry, plate surface condition (oil,  
scale), plate thickness, preheat, quench, gas type, gas  
flow rate and equipment may produce results different  
from those expected. Some adjustments to proce-  
dures may be necessary to compensate for unique  
individual conditions. Test all procedures duplicating  
actual field conditions.  
DRAG thru 1/16"  
Standoff  
Output Setting  
Min. thru Mid. Range  
Output set below 45 Amps.  
• The nozzle may be dragged on the metal surface,  
touching it lightly to the surface after piercing a hole.  
Current control should be set below the mid-range.  
• Do not allow cable or body to contact hot surface.  
PRO-CUT 80  
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B-8  
B-8  
OPERATION  
1. Occasionally an oxide layer may form over the tip  
of the electrode, creating an insulating barrier  
between the electrode and nozzle. This will result in  
the tripping of the Pro-Cut's safety circuit. When  
this happens, turn the power off, remove the noz-  
zle and electrode and use the electrode to rub  
against the inside bottom surface of the nozzle.  
This will help remove any oxide buildup. Replace  
the nozzle, turn on the power and continue cutting.  
If the Parts-in-Place circuit (safety status indicator  
light) continues to trip after cleaning the consum-  
ables, replace them with a new set. Do not contin-  
ue to cut with excessively worn consumables as  
this can cause damage to the torch head and will  
degrade cut quality.  
THICK SECTIONS OF METAL  
Torch Standoff  
Machine Output Setting  
45  
1/8" thru 3/16"  
Standoff  
Output Setting  
Mid. thru Max. Range  
Output set above 45 Amps.  
2. To improve consumable life, here are some sug-  
gestions that may be useful:  
a. Never drag the nozzle on the work surface if  
the output control knob is above 45 Amps.  
• The best quality and consumable life will be  
obtained by holding the torch off the surface about  
3/16 in. (4.7mm). Too long an arc may compromise  
cut quality and consumable life. The nozzle should  
NOT be dragged on the work.  
b. Make sure the air supply to the Pro-Cut is  
clean and free of oil. Use several extra in-line  
filters if necessary.  
• Use of the S22151 Drag Cup will maintain the prop-  
er standoff. The only time not to use the drag cup  
when the output control is set above mid-range is in  
special, tight corners. Always hold at least a 1/8 in.  
(3.2mm) standoff in those situations.  
c. Use the lowest output setting possible to  
make a good quality cut at the desired cut  
speed.  
d. Minimize dross buildup on the nozzle tip by  
starting the cut from the edge of the plate  
when possible.  
• If piercing is required, slowly lower the torch at an  
angle of about 30° to blow the dross away from the  
torch tip and slowly rotate the torch to a vertical  
position as the arc becomes deeper. This process  
will blow a lot of molten metal and dross. Be care-  
ful! Blow the dross away from the torch, the opera-  
tor and any flammable objects.  
e. Pierce cutting should be done only when nec-  
essary. If piercing, angle the torch about 30°  
from the plane perpendicular to the work-  
piece, transfer the arc, then bring the torch  
perpendicular to the work and begin parallel  
movement.  
• Where possible, start the cut from the edge of the  
workpiece.  
f. Reduce the number of pilot arc starts without  
transferring to the work.  
• Keep moving! A steady speed is necessary. Do not  
pause.  
g. Reduce the pilot arc time before transferring to  
the work.  
• Do not allow the torch cable or body to contact a  
hot surface.  
h. Set air pressure to recommended setting. A  
higher or lower pressure will cause turbulence  
in the plasma arc, eroding the orifice of the  
nozzle tip.  
SUGGESTIONS FOR EXTRA UTILITY  
FROM THE PRO-CUT SYSTEM  
i. Use only Lincoln consumable parts. These  
parts are patented. Using any other replace-  
ment consumables may cause damage to the  
torch or reduce cut quality.  
WARNING  
ELECTRIC SHOCK can kill.  
• Turn off machine at the disconnect  
switch on the front of the machine  
before tightening, cleaning or replac-  
ing consumables.  
PRO-CUT 80  
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B-9  
B-9  
OPERATION  
MACHINE INTERFACE  
The PRO-CUT 80 comes standard with a machine  
interface. Interface signals provided include: arc start,  
arc initiated, and arc voltage. These signals are acces-  
sible through the 14 pin MS connector on the case  
front.  
ARC START:  
The Arc Start circuit allows for triggering of the power  
source to commence cutting. This circuit can be  
accessed through pins K and M of the 14 pin MS con-  
nector. The circuit has a 17 VDC nominal open circuit  
voltage and requires a dry contact closure to activate.  
ARC INITIATED:  
The Arc Initiated circuit provides information as to  
when a cutting arc has transferred to the work piece.  
This circuit can be accessed through pins I and J of the  
14 pin MS connector.The circuit provides a dry contact  
closure when the arc has transferred. Input to this cir-  
cuit should be limited to 0.3 A for either 120VAC or  
30VDC.  
ARC VOLTAGE:  
The Arc Voltage circuit can be used for activating a  
torch height control. This circuit can be accessed  
through pins D and G of the 14 pin MS connector. The  
circuit provides full electrode to work arc voltage (no  
voltage divider, 335VDC maximum).  
Arc Start  
K=2A  
M=4A  
Arc Initiated  
J=347  
I=348  
L
H
N
C
G=343  
D=344  
F
E
Arc Voltage  
14-PIN BOX RECEPTACLE, FRONT VIEW  
Users wishing to utilize the Machine Interface can  
order a K867 Universal Adapter (please adhere to the  
pin locations stated above) or manufacture a 14 pin MS  
connector cable assembly.  
PRO-CUT 80  
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B-10  
B-10  
NOTES  
PRO-CUT 80  
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Section C-1  
Section C-1  
TABLE OF CONTENTS  
- ACCESSORIES -  
Accessories...........................................................................................................................Section C  
Options/Accessories...................................................................................................................C-2  
PRO-CUT 80  
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C-2  
C-2  
ACCESSORIES  
ALWAYS USE GENUINE LINCOLN ELECTRIC  
ELECTRODES AND VORTECH™ NOZZLES  
GENERAL OPTIONS /  
ACCESSORIES  
• Only Genuine Lincoln Electric consumables yield  
the best cutting performance for the PRO-CUT 80.  
The following options/accessories are available for  
your PRO-CUT 80 from your local Lincoln Distributor.  
• The patent pending VORTECH™ nozzle provides  
an extra “kick” of swirl as the arc exits the nozzle,  
which improves cutting performance. No other noz-  
zle has this capability or can match its performance.  
K1681-1 Undercarriage - A valet style undercarriage  
with pull-out handle for machine only. Provides torch  
and work cable storage.  
S22147-043 - Vortech™ nozzle with an .043” (1.2 mm)  
Orifice (For 35 - 60 Amps)  
S22147-053 - Vortech™ nozzle with an .053” (1.3 mm)  
Orifice (For 60 - 85 Amps)  
S22147-082 - VortechTM nozzle with an .082” (2.1 mm)  
Orifice (For Gouging at 60 -85 Amps)  
S22149 - Electrode - replacement electrodes for cut-  
ting.  
S22150 - Shield Cup - This shields the torch tip and  
provides more visibility to the workpiece than the drag  
cup. Note the shield cup does not prevent the torch tip  
from touching the workpiece.  
S22151 - Drag Cup - The drag cup protects the torch  
by preventing the torch from touching the workpiece.  
K1571 Series - PCT 80 Torches come in 25’ and 50’  
lengths in either hand held or mechanized versions.  
PRO-CUT 80  
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Section D-1  
Section D-1  
TABLE OF CONTENTS  
-MAINTENANCE-  
Maintenance .........................................................................................................................Section D  
Safety Precautions......................................................................................................................D-2  
Input Filter Capacitor Discharge Procedure...............................................................................D-2  
Routine Maintenance..................................................................................................................D-3  
Periodic Maintenance.................................................................................................................D-3  
Major Component Locations .....................................................................................................D-4  
PRO-CUT 80  
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D-2  
D-2  
MAINTENANCE  
4. Obtain a high resistance and high wattage resistor  
(25-1000 ohms and 25 watts minimum). This resis-  
tor is not supplied with machine. NEVER USE A  
SHORTING STRAP FOR THIS PROCEDURE.  
WARNING  
ELECTRIC SHOCK can kill.  
5. Locate the two capacitor terminals (large hex head  
cap screws) at the bottom of the Power Board  
shown in Figure D.1.  
• Have an electrician install and service  
this equipment.  
• Turn the input power off at the fuse box  
before working on equipment.  
6. Use electrically insulated gloves and insulated pli-  
ers. Hold the body of the resistor and connect  
resistor leads across the two capacitor terminals.  
Hold the resistor in place for 10 seconds. DO NOT  
TOUCH CAPACITOR TERMINALS WITH YOUR  
BARE HANDS.  
• Do not touch electrically hot parts.  
• Prior to performing preventative maintenance, per-  
form the following capacitor discharge procedure to  
avoid electric shock.  
7. Repeat the discharge procedure for the other  
capacitor.  
INPUT FILTER CAPACITOR  
DISCHARGE PROCEDURE  
8. Check voltage across the terminals of all capaci-  
tors with a DC voltmeter. Polarity of capacitor ter-  
minals is marked on the Power Board above termi-  
nals. Voltage should be zero. If any voltage  
remains, repeat this capacitor discharge proce-  
dure.  
1. Turn off input power or disconnect input power  
lines.  
2. Remove the 5/16 in. hex head screws from the side  
and top of the machine and remove wrap-around  
machine cover.  
3. Be careful not to make contact with the capacitor  
terminals that are located on the top and bottom of  
the Power Board on the right side of the machine.  
FIGURE D.1 — LOCATION OF INPUT FILTER CAPACITOR TERMINALS  
POWER  
BOARD  
CAPACITOR  
TERMINALS  
POWER  
RESISTOR  
RIGHT SIDE OF MACHINE  
INSULATED  
PLIERS  
INSULATED  
GLOVES  
PRO-CUT 80  
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D-3  
D-3  
MAINTENANCE  
ROUTINE MAINTENANCE  
PERIODIC MAINTENANCE  
1. Keep the cutting or gouging area and the area  
around the machine clean and free of combustible  
materials. No debris should be allowed to collect  
which could obstruct air flow to the machine.  
WARNING  
ELECTRIC SHOCK can kill.  
2. Every 6 months or so, the machine should be  
cleaned with a low pressure airstream. Keeping the  
machine clean will result in cooler operation and  
higher reliability. Be sure to clean these areas. SEE  
FIGURE D.2  
• Turn off machine at the disconnect  
switch on the front of the machine  
before tightening, cleaning or replacing  
consumables.  
- Power, Output and Control printed circuit boards  
and heat sinks  
Change consumables as required.  
- Power Switch  
- Main Transformer  
- Input Rectifier  
1. Thermal Protection  
Two thermostats protect the machine from excessive  
operating temperatures. Excessive temperatures may  
be caused by a lack of cooling air or by operating the  
machine beyond the duty cycle and output rating. If  
excessive operating temperatures should occur, the  
yellow thermal LED will light and the thermostat will  
prevent output voltage or current.  
3. Examine the sheet metal case for dents or break-  
age. Repair the case as required. Keep the case in  
good condition to insure that high voltage parts are  
protected and correct spacings are maintained. All  
external sheet metal screws must be in place to  
insure case strength and electrical ground continu-  
ity.  
Thermostats are self-resetting once the machine cools  
sufficiently. If the thermostat shutdown was caused by  
excessive output or duty cycle and the fan is operat-  
ing normally, the Power Switch may be left on and the  
reset should occur within a 15 minute period. If the fan  
is not turning or the air intake louvers were obstructed,  
then the power must be switched off and the fan prob-  
lem or air obstruction must be corrected.  
4. Check the air regulator filter to be sure it does not  
become clogged. The air filter on the machine is  
self draining and will not have to be emptied.  
5. Check the filter element every several months to  
see if it is clogged (weekly in very dirty environ-  
ments). Replace if necessary by first removing the  
two screws that attach the filter cage to the back  
panel assembly, then slide the cage away from the  
back of the machine and remove. Next, twist the  
clear filter bowl until it comes off (be careful not to  
lose the o-ring seated at the top of the bowl  
threads). Unscrew the filter element and replace  
with new element. Assemble parts in reverse order  
as described above.  
2. Filter Capacitor Conditioning (PRO-CUT 80, 400-  
460 VAC only)  
A protection circuit is included to monitor the voltage  
across filter capacitors C1 and C2. In the event that  
the capacitor voltage is too high, the protection circuit  
will prevent output. The protection circuit may prevent  
output providing all these circumstances are met:  
a. Machine is connected for 400-460 or  
460-575 VAC input.  
6. Inspect the cable periodically for any slits or punc-  
ture marks in the cable jacket. Replace if neces-  
sary. Check to make sure that nothing is crushing  
the cable and blocking the flow of air through the  
air tube inside. Also, check for kinks in the cable  
periodically and relieve any so as not to restrict the  
flow of air to the torch.  
b. Machine did not have power applied for many  
months.  
c. Machine will not produce output when power is  
first switched on.  
If these circumstances apply, the proper action is to  
switch the machine on and let it idle for up to 30 min-  
utes. This is required to condition the filter capacitors  
after an extended storage time. The protection circuit  
will automatically reset once the capacitor condition-  
ing and resultant voltage levels are acceptable. It may  
be necessary to turn the power switch off and back on  
again after this period.  
PRO-CUT 80  
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D-4  
D-4  
Maintenance  
FIGURE D.2 – MAJOR COMPONENT LOCATIONS  
1. Case Front  
2. Base and Case Back  
3. Center Panel Assembly  
4. Output Board Heatsink  
5. Power Board Assembly  
6. Case Wraparound  
6
4
3
5
1
2
PRO-CUT 80  
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Section E-1  
Section E-1  
TABLE OF CONTENTS  
-THEORY OF OPERATION SECTION-  
Theory of Operation .............................................................................................................Section E  
General Description ....................................................................................................................E-2  
Input Line Voltage, Contactor and Main Transformer.................................................................E-2  
Precharge and Protection ...........................................................................................................E-3  
Main Transformer ........................................................................................................................E-4  
Output Board and Torch .............................................................................................................E-5  
Control and Display Boards........................................................................................................E-6  
Protection Circuits ......................................................................................................................E-7  
Overload Protection..............................................................................................................E-7  
Thermal Protection ...............................................................................................................E-7  
Insulated Gate Bipolar Transistor (IGBT) Operation ...................................................................E-8  
Pulse Width Modulation (PWM)..................................................................................................E-9  
Minimum Output...................................................................................................................E-9  
Maximum Output..................................................................................................................E-9  
FIGURE E.1 – PRO-CUT 80 BLOCK LOGIC DIAGRAM  
WORK  
NOZZLE  
ELECTRODE  
POWER BOARD  
TORCH  
CONNECTOR  
MAIN  
TRANSFORMER  
2
CR 1&  
OUTPUT BOARD  
RELAY  
E
L
INPUT  
LINE  
SWITCH  
IGBT  
E
C
T
INPUT  
RECTIFIER  
R
O
D
E
CAPACITOR  
CHOKE  
S
O
L
R
E
C
O
N
N
E
C
T
PILOT  
TRANSISTOR  
IGBT  
IGBT  
E
N
O
I
D
CURRENT  
TRANSFORMER  
TRIGGER & SAFETY  
S
W
I
CAPACITOR  
T
AIR  
SOLENOID  
C
H
IGBT  
P
TRIGGER & SAFETY  
AIR  
PRESSURE  
SWITCH  
R
O
T
E
C
T
I
REMOTE  
CR 1& 2  
RELAY  
DRIVE  
IGBT  
INTERFACE  
RECEPTACLE  
"A"  
GATE  
SIGNALS  
SIGNAL  
ELECTRODE & TRANSFER  
CURRENT FEEDBACK  
L
O
N
SIGNAL  
E
A
D
PILOT ENABLE  
CONTROL BOARD  
ELECTRODE SOLENOID ENABLE  
AIR SOLENOID ENABLE  
18/36VAC  
A
I
T
H
E
R
M
A
L
S
A
F
E
T
Y
R
E
R
THERMOSTATS  
A
D
Y
L
O
W
OUTPUT  
CONTROL  
DISPLAY BOARD  
12VAC  
24VAC  
115VAC  
AUXILIARY  
TRANSFORMER  
FAN  
MOTOR  
PRO-CUT 80  
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E-2  
E-2  
THEORY OF OPERATION  
FIGURE E.2 – INPUT LINE VOLTAGE  
WORK  
NOZZLE  
ELECTRODE  
POWER BOARD  
TORCH  
CONNECTOR  
MAIN  
TRANSFORMER  
2
CR 1&  
OUTPUT BOARD  
RELAY  
E
L
INPUT  
LINE  
SWITCH  
IGBT  
E
C
T
INPUT  
RECTIFIER  
R
O
D
E
CAPACITOR  
CHOKE  
S
O
L
R
E
C
O
N
N
E
C
T
PILOT  
TRANSISTOR  
IGBT  
IGBT  
E
N
O
I
D
CURRENT  
TRANSFORMER  
TRIGGER & SAFETY  
S
W
I
CAPACITOR  
T
AIR  
SOLENOID  
C
H
IGBT  
P
TRIGGER & SAFETY  
AIR  
PRESSURE  
SWITCH  
R
O
T
E
C
T
I
REMOTE  
CR 1& 2  
RELAY  
DRIVE  
IGBT  
INTERFACE  
RECEPTACLE  
"A"  
GATE  
SIGNALS  
SIGNAL  
ELECTRODE & TRANSFER  
CURRENT FEEDBACK  
L
O
N
SIGNAL  
E
A
D
PILOT ENABLE  
CONTROL BOARD  
ELECTRODE SOLENOID ENABLE  
AIR SOLENOID ENABLE  
18/36VAC  
A
I
T
H
E
R
M
A
L
S
A
F
E
T
Y
R
E
R
THERMOSTATS  
A
D
Y
L
O
W
OUTPUT  
CONTROL  
DISPLAY BOARD  
12VAC  
24VAC  
115VAC  
AUXILIARY  
TRANSFORMER  
FAN  
MOTOR  
GENERAL DESCRIPTION  
INPUT LINE VOLTAGE, SWITCH  
AND MAIN TRANSFORMER  
The PRO-CUT 80 is a constant current, continuous  
control plasma cutting power source. The inverter  
based power supply design is controlled by a micro-  
processor control board. The control system has a  
safety mechanism to insure that the nozzle and elec-  
trode are in place before cutting or gouging. The PRO-  
CUT 80 initiates the plasma arc with a simple, yet reli-  
able, touch start mechanism. This system eliminates  
many of the problems associated with hi-frequency  
type start systems. When powered up, the machine  
performes some rudimentary self diognostics.  
The single-phase or three-phase input power is con-  
nected to the machine, via an input line cord, to a  
switch located on the front panel.  
A reconnect panel and voltage range switch allow the  
user to configure the machine for either a low or high  
input voltage and also connect the auxiliary trans-  
former for the appropriate input voltage.  
The auxiliary transformer develops the appropriate AC  
voltages to operate the cooling fan, the control board  
and the plasma output board.  
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.  
PRO-CUT 80  
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E-3  
E-3  
THEORY OF OPERATION  
WORK  
NOZZLE  
ELECTRODE  
POWER BOARD  
TORCH  
CONNECTOR  
MAIN  
TRANSFORMER  
2
CR 1&  
OUTPUT BOARD  
RELAY  
E
L
INPUT  
LINE  
SWITCH  
IGBT  
E
C
T
INPUT  
RECTIFIER  
R
O
D
E
CAPACITOR  
CHOKE  
S
O
L
R
E
C
O
N
N
E
C
T
PILOT  
TRANSISTOR  
IGBT  
IGBT  
E
N
O
I
D
CURRENT  
TRANSFORMER  
TRIGGER & SAFETY  
S
W
I
CAPACITOR  
T
AIR  
SOLENOID  
C
H
IGBT  
P
TRIGGER & SAFETY  
AIR  
PRESSURE  
SWITCH  
R
O
T
E
C
T
I
REMOTE  
CR 1& 2  
RELAY  
DRIVE  
IGBT  
INTERFACE  
RECEPTACLE  
"A"  
GATE  
SIGNALS  
SIGNAL  
ELECTRODE & TRANSFER  
CURRENT FEEDBACK  
L
O
N
SIGNAL  
E
A
D
PILOT ENABLE  
CONTROL BOARD  
ELECTRODE SOLENOID ENABLE  
AIR SOLENOID ENABLE  
18/36VAC  
A
I
T
H
E
R
M
A
L
S
A
F
E
T
Y
R
E
R
THERMOSTATS  
A
D
Y
L
O
W
OUTPUT  
CONTROL  
DISPLAY BOARD  
12VAC  
24VAC  
115VAC  
AUXILIARY  
TRANSFORMER  
FAN  
MOTOR  
PRECHARGE AND PROTECTION  
The input voltage is rectified by the input rectifier. The  
resultant DC voltage is applied, through the reconnect  
switch, to the power board. The power board contains  
precharging circuitry for the safe charging of the input  
filter capacitors. Once the capacitors are precharged  
and balanced the control board activates the CR1+  
CR2 input relays. This connects full input power to the  
filter capacitors. When the filter capacitors are fully  
charged they act as power supplies for the IGBT  
switching circuit. The Insulated Gate Bipolar Tran-  
sistors supply the main transformer primary winding  
with DC current flow. See IGBT Operation discussion  
and diagrams in this section.  
The power board also monitors the filter capacitors for  
voltage balance and under or overvoltage. If either  
should occur, the appropriate signal is sent to the con-  
trol board to deactivate the CR1+ CR2 input relay. The  
machine output will also be disabled.  
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.  
PRO-CUT 80  
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E-4  
E-4  
THEORY OF OPERATION  
FIGURE E.4 – MAIN TRANSFORMER  
WORK  
NOZZLE  
ELECTRODE  
POWER BOARD  
TORCH  
CONNECTOR  
MAIN  
TRANSFORMER  
2
CR 1&  
OUTPUT BOARD  
RELAY  
E
L
INPUT  
LINE  
SWITCH  
IGBT  
E
C
T
INPUT  
RECTIFIER  
R
O
D
E
CAPACITOR  
CHOKE  
S
O
L
R
E
C
O
N
N
E
C
T
PILOT  
TRANSISTOR  
IGBT  
IGBT  
E
N
O
I
D
CURRENT  
TRANSFORMER  
TRIGGER & SAFETY  
S
W
I
CAPACITOR  
T
AIR  
SOLENOID  
C
H
IGBT  
P
TRIGGER & SAFETY  
AIR  
PRESSURE  
SWITCH  
R
O
T
E
C
T
I
REMOTE  
CR 1& 2  
RELAY  
DRIVE  
IGBT  
INTERFACE  
RECEPTACLE  
"A"  
GATE  
SIGNALS  
SIGNAL  
ELECTRODE & TRANSFER  
CURRENT FEEDBACK  
L
O
N
SIGNAL  
E
A
D
PILOT ENABLE  
CONTROL BOARD  
ELECTRODE SOLENOID ENABLE  
AIR SOLENOID ENABLE  
18/36VAC  
A
I
T
H
E
R
M
A
L
S
A
F
E
T
Y
R
E
R
THERMOSTATS  
A
D
Y
L
O
W
OUTPUT  
CONTROL  
DISPLAY BOARD  
12VAC  
24VAC  
115VAC  
AUXILIARY  
TRANSFORMER  
FAN  
MOTOR  
MAIN TRANSFORMER  
Each IGBT pair acts as a switch assembly. Each  
assembly feeds a separate, oppositely wound primary  
winding of the main transformer. The reverse direction  
of current flow through the main transformer primaries  
and the offset timing of the IGBT pairs induce an AC  
square wave output signal at the secondary of the  
main transformer.  
The firing of both IGBT pairs occurs during halves of  
the 50 microsecond intervals, creating a constant  
20KHZ output.  
The secondary portion of the main transformer is made  
up of two separate windings. One secondary winding  
supplies the electrode-to-work voltage. This is the  
high current winding, which is capable of supplying  
maximum output current during the cutting process.  
The DC current flow through each primary winding is  
redirected or "clamped" back to each respective filter  
capacitor when the IGBTs are turned off. This is need-  
ed due to the inductance of the transformer primary  
winding.  
The other secondary winding supplies the electrode-  
to-nozzle voltage for the pilot arc current. The con-  
ductor in this winding is smaller since the pilot current  
is considerably less than the cutting current. While  
one winding is conducting the other winding is at a lim-  
ited voltage and aids in the arc transfer to and from the  
workpiece.  
The primary currents also pass through the current  
transformer, which sends a signal to the control board.  
If the primary currents are not equal, the control board  
compensates by adjusting the IGBT gate signals.  
PRO-CUT 80  
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E-5  
E-5  
THEORY OF OPERATION  
FIGURE E.5 – PLASMA OUTPUT BOARD AND TORCH  
WORK  
NOZZLE  
ELECTRODE  
POWER BOARD  
TORCH  
CONNECTOR  
MAIN  
TRANSFORMER  
2
CR 1&  
OUTPUT BOARD  
RELAY  
E
L
INPUT  
LINE  
SWITCH  
IGBT  
E
C
T
INPUT  
RECTIFIER  
R
O
D
E
CAPACITOR  
CHOKE  
S
O
L
R
E
C
O
N
N
E
C
T
PILOT  
TRANSISTOR  
IGBT  
IGBT  
E
N
O
I
D
CURRENT  
TRANSFORMER  
TRIGGER & SAFETY  
S
W
I
CAPACITOR  
T
AIR  
SOLENOID  
C
H
IGBT  
P
TRIGGER & SAFETY  
AIR  
PRESSURE  
SWITCH  
R
O
T
E
C
T
I
REMOTE  
CR 1& 2  
RELAY  
DRIVE  
IGBT  
INTERFACE  
RECEPTACLE  
"A"  
GATE  
SIGNALS  
SIGNAL  
ELECTRODE & TRANSFER  
CURRENT FEEDBACK  
L
O
N
SIGNAL  
E
A
D
PILOT ENABLE  
CONTROL BOARD  
ELECTRODE SOLENOID ENABLE  
AIR SOLENOID ENABLE  
18/36VAC  
A
I
T
H
E
R
M
A
L
S
A
F
E
T
Y
R
E
R
THERMOSTATS  
A
D
Y
L
O
W
OUTPUT  
CONTROL  
DISPLAY BOARD  
12VAC  
24VAC  
115VAC  
AUXILIARY  
TRANSFORMER  
FAN  
MOTOR  
OUTPUT BOARD AND TORCH  
The output board contains an Insulated Gate Bipolar  
Transistor (IGBT) which, upon receiving a pilot signal from  
the control board, either enables or disables the current in  
the pilot winding. The cutting and pilot rectifier diodes are  
also incorporated in the output board. There are two  
diodes for the pilot winding and four diodes for the cutting  
winding.  
A copper nozzle with a patented internal swirl is used to  
focus the arc. A small, precise hole in the end of the noz-  
zle constricts the arc and increases the current density.  
As the air enters the torch head, it is directed between  
the electrode and nozzle for maximum electrode cooling.  
A portion of the cooling air exits the chamber through  
vents in the side of the nozzle. A swirl texture located  
inside the bottom of the nozzle increases the plenum air  
swirl strength, and improves arc start reliability and parts-  
in-place verification.  
There are two P.C. board mounted current sensors. One  
sensor regulates pilot and cutting current. The other sen-  
sor indicates to the control board when and how much  
current transfers to the workpiece.  
The output board also includes the trigger circuitry, the gas  
solenoid driver, the electrode solenoid driver and the torch  
parts-in-place circuitry and remote interface circutry.  
Plasma arc initiation occurs as follows: First, in the idle  
state, a spring inside the torch head pushes the piston  
and electrode forward to make continuity with the nozzle.  
When the trigger is pulled, air flow begins and creates  
enough back force on the electrode to overcome the  
force of the spring. However, the solenoid valve allows  
enough forward force on the piston to maintain continu-  
ity between the consumables. After this continuity has  
been verified by the Pro-Cut’s parts-in-place circuit, out-  
put current is established and regulated. Once the cur-  
rent stabilizes, the solenoid valve turns off, removing the  
forward force on the piston. The back pressure drives  
the piston and electrode away from the nozzle, creating  
the plasma arc. The air stream forces the arc out the ori-  
fice of the nozzle. This appears as a pilot arc, which can  
then be transferred for cutting.  
The output choke, which is in series with both the pilot cir-  
cuit and the cutting circuit, provides current filtering to  
enhance arc stability.  
The PCT 80 torch uses a patented touch start mechanism  
that provides superior starting performance over other  
touch start systems. The torch head consists of 3 major  
parts: torch body, insulator and piston. The insulator pro-  
vides an electrical barrier between the piston and torch  
body. The piston provides a path for electrical current to  
the electrode. The piston also drives the electrode to the  
nozzle for arc initiation. The torch body contains the main  
torch components: the trigger, pilot arc, cutting arc, and air  
flow systems are included.  
PRO-CUT 80  
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E-6  
E-6  
THEORY OF OPERATION  
FIGURE E.6 – CONTROL AND DISPLAY BOARDS  
WORK  
NOZZLE  
ELECTRODE  
POWER BOARD  
TORCH  
CONNECTOR  
MAIN  
TRANSFORMER  
2
CR 1&  
OUTPUT BOARD  
RELAY  
E
L
INPUT  
LINE  
SWITCH  
IGBT  
E
C
T
INPUT  
RECTIFIER  
R
O
D
E
CAPACITOR  
CHOKE  
S
O
L
R
E
C
O
N
N
E
C
T
PILOT  
TRANSISTOR  
IGBT  
IGBT  
E
N
O
I
D
CURRENT  
TRANSFORMER  
TRIGGER & SAFETY  
S
W
I
CAPACITOR  
T
AIR  
SOLENOID  
C
H
IGBT  
P
TRIGGER & SAFETY  
AIR  
PRESSURE  
SWITCH  
R
O
T
E
C
T
I
REMOTE  
CR 1& 2  
RELAY  
DRIVE  
IGBT  
INTERFACE  
RECEPTACLE  
"A"  
GATE  
SIGNALS  
SIGNAL  
ELECTRODE & TRANSFER  
CURRENT FEEDBACK  
L
O
N
SIGNAL  
E
A
D
PILOT ENABLE  
CONTROL BOARD  
ELECTRODE SOLENOID ENABLE  
AIR SOLENOID ENABLE  
18/36VAC  
A
I
T
H
E
R
M
A
L
S
A
F
E
T
Y
R
E
R
THERMOSTATS  
A
D
Y
L
O
W
OUTPUT  
CONTROL  
DISPLAY BOARD  
12VAC  
24VAC  
115VAC  
AUXILIARY  
TRANSFORMER  
FAN  
MOTOR  
CONTROL AND DISPLAY BOARDS  
The control board receives status and analog feed-  
back signals from the output board, display board,  
power board and various sensors. The processor  
interprets these signals, makes decisions and changes  
machine mode and output to satisfy the requirements  
as defined by the internal software. The control board  
regulates the output of the machine by controlling the  
IGBT switching times through pulse width modulation  
circuitry. See Pulse Width Modulation in this section.  
The display board receives commands from the con-  
trol board and, via indicator lights, communicates  
PRO-CUT 80 status and operating conditions to the  
user.  
PRO-CUT 80  
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E-7  
E-7  
THEORY OF OPERATION  
THERMAL PROTECTION  
PROTECTION CIRCUITS  
Two thermostats protect the machine from excessive  
operating temperatures. One thermostat is located on  
the output choke and the other on the power board  
IGBT heat sink. Excessive temperatures may be  
caused by a lack of cooling air or by operating the  
machine beyond the duty cycle and output rating. If  
excessive operating temperatures should occur, the  
thermal status indicator will light and the thermostat  
will prevent output voltage or current.  
Protection circuits are designed into the PRO-CUT 80  
machine to sense trouble and shut down the machine  
before the trouble damages internal machine compo-  
nents. Both overload and thermal protection circuits  
are included.  
OVERLOAD PROTECTION  
The PRO-CUT 80 is electrically protected from pro-  
ducing higher than normal output currents. If the out-  
put current exceeds 85-90 amps, an electronic pro-  
tection circuit limits the current to within the capabili-  
ties of the machine.  
Thermostats are self-resetting once the machine cools  
sufficiently. If the thermostat shutdown was caused  
by excessive output or duty cycle and the fan is oper-  
ating normally, the power switch may be left on and  
the reset should occur within a 15 minute period. If  
the fan is not turning or the air intake louvers are  
obstructed, the input power must be removed and the  
fan problem or air obstruction must be corrected.  
Another protection circuit monitors the voltage across  
the input filter capacitors. If the filter capacitor voltage  
is too high, too low or not balanced the protection cir-  
cuit may prevent machine output.  
PRO-CUT 80  
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E-8  
E-8  
THEORY OF OPERATION  
INSULATED GATE BIPOLAR  
TRANSISTOR (IGBT) OPERATION  
An IGBT is a type of transistor. IGBTs are semicon-  
ductors well suited for high frequency switching and  
high current applications.  
Drawing B shows the IGBT in an active mode. When  
the gate signal, a positive DC voltage relative to the  
source, is applied to the gate terminal of the IGBT, it  
is capable of conducting current. A voltage supply  
connected to the drain terminal will allow the IGBT to  
conduct and supply current to circuit components  
coupled to the source. Current will flow through the  
conducting IGBT to downstream components as long  
as the positive gate signal is present. This is similar  
to turning ON a light switch.  
Drawing A shows an IGBT in a passive mode. There  
is no gate signal, zero volts relative to the source, and  
therefore, no current flow. The drain terminal of the  
IGBT may be connected to a voltage supply; but since  
there is no conduction the circuit will not supply cur-  
rent to components connected to the source. The cir-  
cuit is turned off like a light switch in the OFF position.  
FIGURE E.7 – CONTROL AND DISPLAY BOARDS  
POSITIVE  
VOLTAGE  
APPLIED  
GATE  
GATE  
SOURCE  
SOURCE  
n +  
n +  
n +  
n +  
p
BODY REGION  
p
BODY REGION  
DRAIN DRIFT REGION  
DRAIN DRIFT REGION  
n -  
n -  
n +  
p +  
BUFFER LAYER  
n +  
p +  
BUFFER LAYER  
INJECTING LAYER  
INJECTING LAYER  
DRAIN  
DRAIN  
B. ACTIVE  
A. PASSIVE  
PRO-CUT 80  
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E-9  
E-9  
THEORY OF OPERATION  
The positive portion of the signal represents one IGBT  
group1 conducting for 1 microsecond. The negative  
portion is the other IGBT group1. The dwell time (off  
time) is 48 microseconds (both IGBT groups off).  
Since only 2 microseconds of the 50-microsecond  
time period is devoted to conducting, the output  
power is minimized.  
PULSE WIDTH MODULATION  
The term PULSE WIDTH MODULATION describes  
how much time is devoted to conduction in the posi-  
tive and negative portions of the cycle. Changing the  
pulse width is known as MODULATION. Pulse Width  
Modulation (PWM) is the varying of the pulse width  
over the allowed range of a cycle to affect the output  
of the machine.  
MAXIMUM OUTPUT  
By holding the gate signals on for 22 microseconds  
each and allowing only 3 microseconds of dwell time  
(off time) during the 50-microsecond cycle, the output  
is maximized. The darkened area under the top curve  
can be compared to the area under the bottom curve.  
The more dark area under the curve, the more power  
is present.  
MINIMUM OUTPUT  
By controlling the duration of the gate signal, the IGBT  
is turned on and off for different durations during a  
cycle. The top drawing below shows the minimum  
output signal possible over a 50-microsecond time  
period.  
1
An IGBT group consists of two IGBT modules feeding one transformer primary winding.  
FIGURE E.8 – TYPICAL IGBT OUTPUTS  
sec  
sec  
sec  
48  
50  
sec  
MINIMUM OUTPUT  
sec  
22  
sec  
sec  
22  
3
sec  
50  
MAXIMUM OUTPUT  
PRO-CUT 80  
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E-10  
E-10  
NOTES  
PRO-CUT 80  
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Section F-1  
Section F-1  
TABLE OF CONTENTS  
TROUBLESHOOTING & REPAIR SECTION  
Troubleshooting & Repair Section.................................................................................Section F  
How to Use Troubleshooting Guide ......................................................................................F-2  
PC Board Troubleshooting Procedures and Replacement ...................................................F-3  
Troubleshooting Guide...........................................................................................................F-4  
Test Procedures  
Input Filter Capacitor Discharge Procedure..................................................................F-10  
Input Rectifier Test ........................................................................................................F-12  
Primary Power Board Resistance Test and Capacitor Voltage Test.............................F-15  
Output Power Board Resistance Test...........................................................................F-20  
Torch Continuity and Solenoid Test ..............................................................................F-23  
Air/Gas Solenoid Test....................................................................................................F-25  
T2 Auxiliary Transformer Test........................................................................................F-27  
Trigger Circuit Test ........................................................................................................F-30  
Low Voltage Circuit Test................................................................................................F-35  
Replacement Procedures  
Control Board Removal and Replacement ...................................................................F-40  
Display Board Removal and Replacement ...................................................................F-43  
Output Power Board Removal and Replacement.........................................................F-46  
Primary Power Board and Filter Capacitor Removal and Replacement ......................F-50  
Input Rectifier Bridge Removal and Replacement........................................................F-54  
Retest after Repair ........................................................................................................F-57  
PRO-CUT 80  
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F-2  
F-2  
TROUBLESHOOTING & REPAIR  
HOW TO USE TROUBLESHOOTING GUIDE  
WARNING  
Service and repair should be performed by only Lincoln Electric Factory Trained Personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician and machine  
operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please  
observe all safety notes and precautions detailed throughout this manual.  
This Troubleshooting Guide is provided to help  
you locate and repair possible machine malfunc-  
tions. Simply follow the three-step procedure  
listed below.  
Step 3. PERFORM COMPONENT TESTS. The  
last column, labeled “Recommended Course of  
Action” lists the most likely components that may  
have failed in your machine. It also specifies the  
appropriate test procedure to verify that the sub-  
ject component is either good or bad. If there are  
a number of possible components, check the  
components in the order listed to eliminate one  
possibility at a time until you locate the cause of  
your problem.  
Step 1. LOCATE PROBLEM (SYMPTOM). Look  
under the column labeled “PROBLEM (SYMP-  
TOMS). This column describes possible symp-  
toms that the machine may exhibit. Find the list-  
ing that best describes the symptom that the  
machine is exhibiting. Symptoms are grouped  
into four main categories: Output Problems,  
Function Problems, Cutting Problems and LED  
Function Problems.  
All of the referenced test procedures referred to in  
the Troubleshooting Guide are described in detail  
at the end of this chapter. Refer to the  
Troubleshooting and Repair Table of Contents to  
locate each specific Test Procedure. All of the  
referred to test points, components, terminal  
strips, etc., can be found on the referenced elec-  
trical wiring diagrams and schematics. Refer to  
the Electrical Diagrams Section Table of Contents  
to locate the appropriate diagram.  
Step 2. PERFORM EXTERNAL TESTS. The  
second column, labeled “POSSIBLE AREAS OF  
MISADJUSTMENT(S)”, lists the obvious external  
possibilities that may contribute to the machine  
symptom. Perform these tests/checks in the  
order listed. In general, these tests can be con-  
ducted without removing the case wrap-around  
cover.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs  
safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before  
you proceed. Call 1-800-833-9353.  
PRO-CUT 80  
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F-3  
F-3  
TROUBLESHOOTING & REPAIR  
PC BOARD TROUBLESHOOTING PROCEDURES  
• Remove the PC Board from the static-shielding bag  
and place it directly into the equipment. Don’t set  
the PC Board on or near paper, plastic or cloth which  
could have a static charge. If the PC Board can’t be  
installed immediately, put it back in the static-  
shielding bag.  
WARNING  
ELECTRIC SHOCK can kill.  
Have an electrician install and service  
this equipment. Turn the machine OFF  
before working on equipment. Do not  
touch electrically hot parts.  
• If the PC Board uses protective shorting jumpers,  
don’t remove them until installation is complete.  
• If you return a PC Board to The Lincoln Electric  
Company for credit, it must be in the static-shielding  
bag. This will prevent further damage and allow  
proper failure analysis.  
Sometimes machine failures appear to be due to PC  
board failures. These problems can sometimes be  
traced to poor electrical connections. To avoid prob-  
lems when troubleshooting and replacing PC boards,  
please use the following procedure:  
4. Test the machine to determine if the failure symp-  
tom has been corrected by the replacement PC  
board.  
1. Determine to the best of your technical ability that  
the PC board is the most likely component caus-  
ing the failure symptom.  
NOTE: Allow the machine to heat up so that all elec-  
trical components can reach their operating  
temperature.  
2. Check for loose connections at the PC board to  
assure that the PC board is properly connected.  
5. Remove the replacement PC board and substitute  
it with the original PC board to recreate the original  
problem.  
3. If the problem persists, replace the suspect PC  
board using standard practices to avoid static  
electrical damage and electrical shock. Read the  
warning inside the static resistant bag and perform  
the following procedures:  
a. If the original problem does not reappear  
by substituting the original board, then the  
PC board was not the problem. Continue  
to look for bad connections in the control  
wiring harness, junction blocks, and termi-  
nal strips.  
PC Board can be damaged by  
static electricity.  
b. If the original problem is recreated by the  
substitution of the original board, then the  
PC board was the problem. Reinstall the  
replacement PC board and test the  
machine.  
• Remove your body’s static charge  
before opening the static-shield-  
ing bag. Wear an anti-static wrist  
strap. For safety, use a 1 Meg  
ohm resistive cord connected to a  
ATTENTION  
Static-Sensitive  
Devices  
Handle only at  
Static-Safe  
grounded part of the equipment  
frame.  
6. Always indicate that this procedure was followed  
when warranty reports are to be submitted.  
• If you don’t have a wrist strap,  
touch an unpainted, grounded,  
part of the equipment frame.  
Keep touching the frame to pre-  
vent static build-up. Be sure not  
to touch any electrically live parts  
at the same time.  
NOTE: Following this procedure and writing on the  
warranty report, “INSTALLED AND SWITCHED  
PC BOARDS TO VERIFY PROBLEM,” will help  
avoid denial of legitimate PC board warranty  
claims.  
Workstations  
Reusable  
Container  
Do Not Destroy  
• Tools which come in contact with the PC Board must  
be either conductive, anti-static or static-dissipative.  
PRO-CUT 80  
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F-4  
F-4  
TROUBLESHOOTING & REPAIR  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
TROUBLESHOOTING GUIDE  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
OUTPUT PROBLEMS  
Major physical or electrical dam- 1. Contact your local authorized 1. Contact the Lincoln Electric  
age is evident when the sheet  
metal cover(s) are removed.  
Lincoln Electric Field Service  
Facility for technical assistance.  
Service Department,  
1-800-833-9353 (WELD).  
Machine is dead – no output – no 1. Make sure that the input power 1. Check the input power switch  
fan – no status indicator lights.  
switch is in the “ON” position.  
(S1) for proper operation. See  
the Wiring Diagram.  
2. Check the input voltage at the  
machine. Input voltage must 2. Check the leads associated  
match the rating plate and the  
reconnect panel.  
with the power switch (S1) and  
the auxiliary transformer (T2) for  
loose or faulty connections.  
See the Wiring Diagram.  
3. Check for blown or missing  
fuses in the input lines and the  
0.6 amp slow blow reconnect 3. Perform the Auxiliary Trans-  
fuse. former Test.  
Machine is dead - not output - no 1. Check the input voltage at the 1. Perform  
the  
Auxiliary  
status indicator lights - fans run.  
machine. Input voltage must  
match the rating plate and the  
reconnect panel.  
Transformer Test.  
2. Perform the Low Voltage  
Circuit Test.  
3. Perform the Input Rectifier  
Test.  
4. The control board may be  
faulty. Replace.  
5. The display board may be  
faulty. Replace.  
All status indicators remain lit 1. The microprocessor has experi- 1. The control board may be  
immediately after power up.  
enced a memory fault. Contact  
your Local Lincoln Authorized  
Field Service Facility.  
faulty. Replace.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
1-800-833-9353.  
PRO-CUT 80  
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F-5  
F-5  
TROUBLESHOOTING & REPAIR  
TROUBLESHOOTING GUIDE  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
FUNCTION PROBLEMS  
All the status lights begin to blink 1. Make sure the PRO-CUT 80 is 1. Perform the Primary Power  
within 5 seconds of power up.  
reconnected correctly for the  
input voltage being applied. Be  
sure to remove input power  
and wait at least one minute  
before changing the position  
Board Resistance Test and  
Capacitor Voltage Test.  
2. Perform the Input Rectifier  
Test.  
of the input voltage range 3. The control board may be  
switch.  
faulty. Replace.  
4. The primary power board may  
be faulty. Replace.  
The machine powers up properly, 1. Make sure the torch is connect- 1. Perform the Auxiliary Trans-  
but there is no response when the  
gun trigger is pulled. Only the  
power LED is lit.  
ed properly to the PRO-CUT 80  
machine.  
former Test.  
2. Perform the Trigger Circuit  
2. Make sure the air supply is con-  
nected and operating properly.  
Test.  
3. Perform the Gas Solenoid  
3. Make sure the torch head con-  
sumable parts are in place and  
in good condition. Replace if  
necessary.  
Test.  
4. Perform the Torch Continuity  
and Solenoid Test.  
5. The control board may be  
faulty. Replace.  
6. The output power board may  
be faulty. Perform the Output  
Board Resistance Test.  
When the torch trigger is pulled, air 1. Make sure the torch consum- 1. Perform the Torch Continuity  
begins to flow; but no pilot arc is  
established.  
ables are in place and in good  
condition. Replace if neces-  
sary.  
and Solenoid Test.  
2. Perform the Low Voltage  
Circuit Test.  
2. Make sure the air pressure is  
set at 70 psi (448 kPa.)  
3. The output board may be faulty.  
Perform the Output Board  
Resistance Test.  
3. Make sure there are no kinks or  
restrictions for air flow in the  
torch cable.  
4. The control board may be  
faulty. Replace.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed.  
Call 1-800-833-9353.  
PRO-CUT 80  
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F-6  
F-6  
TROUBLESHOOTING & REPAIR  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
TROUBLESHOOTING GUIDE  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
FUNCTION PROBLEMS  
The air begins to flow when the 1. Make sure the air pressure is 1. Perform the Torch Continuity  
torch trigger is pulled. There is a  
very brief pilot arc. (Normal is 3  
seconds.) The sequence is repeat-  
ed with subsequent trigger pulls.  
set at 70 psi (448 kPa.)  
and Solenoid Test.  
2. Make sure the torch consum- 2. The output board may be faulty.  
ables are in place and in good  
condition.  
Replace.  
3. The control board may be  
faulty. Replace.  
3. Make sure the air flow is not  
restricted.  
The cutting arc starts but sputters 1. Make sure the operating proce- 1. Perform the Torch Continuity  
badly.  
dure is correct for the process.  
See the Operation section of  
this manual.  
and Solenoid Test.  
2. The output board may be faulty.  
Replace.  
2. Make sure the work clamp is  
connected tightly to the work-  
piece.  
3. The control board may be  
faulty. Replace.  
3. Make sure the torch consum-  
ables are in place and in good  
condition.  
4. Make sure the air supply is not  
contaminated with oil or exces-  
sive water.  
5. Make sure the air pressure is  
set at 70 psi (448 kPa.)  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
1-800-833-9353.  
PRO-CUT 80  
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F-7  
F-7  
TROUBLESHOOTING & REPAIR  
TROUBLESHOOTING GUIDE  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
CUTTING PROBLEMS  
The pilot arc is normal, but the arc 1. Make sure the operating proce- 1. Check the lead connections X2,  
will not transfer to the workpiece.  
dure is correct for the process.  
See the Operation section of  
this manual.  
X4 and B21 at the output board.  
2. Check the output control  
potentiometer (R1). Normal  
resistance is 10 ohms. Also  
check the associated leads for  
loose or faulty connections to  
the display board. See the  
Wiring Diagram.  
2. Make sure the work clamp is  
connected tightly to the work-  
piece.  
3. The workpiece must be electri-  
cally conductive material.  
3. Check leads #216, #218 and  
#219 between the display  
board and the control board.  
Check for loose or faulty con-  
nections.  
Diagram.  
See the Wiring  
4. The control board may be  
faulty. Replace.  
5. The output board may be faulty.  
Perform the Output Board  
Resistance Test.  
6. The display board may be  
faulty. Replace.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed.  
Call 1-800-833-9353.  
PRO-CUT 80  
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F-8  
F-8  
TROUBLESHOOTING & REPAIR  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
TROUBLESHOOTING GUIDE  
PROBLEMS  
POSSIBLE AREAS OF  
RECOMMENDED  
(SYMPTOMS)  
MISADJUSTMENT(S)  
COURSE OF ACTION  
LED FUNCTION PROBLEMS  
The Air Low LED is lit.  
1. Make sure there is at least 70 1. The pressure switch (S5) or  
psi (448 kPa) of air pressure  
connected to the gas connec-  
tion at the back of the PRO-  
CUT 80.  
associated leads may be faulty.  
See the Wiring Diagram.  
2. The control board may be faulty.  
Replace.  
2. Press the purge button and set  
the regulator to 70 psi (448  
kPa). Do not reset the air pres-  
sure while the air is off (not flow-  
ing).  
The Safety LED is flashing.  
1. Make sure there is a Lincoln 1. Perform the Torch Continuity  
PCT 80 torch connected prop-  
and Solenoid Test.  
erly to the PRO-CUT 80.  
2. Check leads “N”, “E”, #364, and  
#369 between the torch recep-  
tacle, the output board, and the  
Transformer. (See the Wiring  
Diagram)  
2. Make sure the torch consum-  
ables are in place and in good  
condition.  
3. The output board may be faulty.  
Replace.  
The Safety LED is lit and steady.  
1. Press the reset button. If the 1. The reset button or associated  
torch and consumables are  
properly installed, the Safety  
LED should turn off.  
wiring may be faulty. See the  
Wiring Diagram.  
2. Perform the Torch Continuity  
and Solenoid Test.  
3. The control board may be faulty.  
Replace.  
4. If the machine operates normal-  
ly with the Safety LED on, the  
display board may be faulty.  
Replace.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed.  
Call 1-800-833-9353.  
PRO-CUT 80  
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F-9  
F-9  
TROUBLESHOOTING & REPAIR  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
TROUBLESHOOTING GUIDE  
PROBLEMS  
POSSIBLE AREAS OF  
RECOMMENDED  
(SYMPTOMS)  
MISADJUSTMENT(S)  
COURSE OF ACTION  
LED FUNCTION PROBLEMS  
The Thermal LED is lit.  
1. One of the machine’s ther- 1. A thermostat may be faulty.  
mostats has tripped. Do not  
turn the PRO-CUT 80 off. Allow  
the machine to cool. The ther-  
mostat(s) will reset themselves.  
Replace.  
2. The control board may be  
faulty. Replace.  
3. If the machine operates normal-  
ly with the Thermal LED lit, the  
display board may be faulty.  
Replace.  
Either the duty cycle has been  
exceeded, the fan is not func-  
tioning or the louvers are  
blocked.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed.  
Call 1-800-833-9353.  
PRO-CUT 80  
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F-10  
F-10  
TROUBLESHOOTING & REPAIR  
INPUT FILTER CAPACITOR DISCHARGE PROCEDURE  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained person-  
nel. Unauthorized repairs performed on this equipment may result in danger to the tech-  
nician or machine operator and will invalidate your factory warranty. For your safety and  
to avoid electrical shock, please observe all safety notes and precautions detailed  
throughout this manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
DESCRIPTION  
This procedure will drain off any charge stored in the two large capacitors that are part  
of the power board assembly. This procedure MUST be performed, as a safety precau-  
tion, before conducting any test or repair procedure that requires you to touch internal  
components of the machine.  
MATERIALS NEEDED  
Volt/Ohmmeter (Multimeter)  
5/16” Nut driver  
Insulated gloves  
Insulated pliers  
High wattage resistor - 25 to 1000 ohms, 25 watts minimum  
This procedure takes approximately 10 minutes to perform.  
PRO-CUT 80  
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F-11  
F-11  
TROUBLESHOOTING & REPAIR  
INPUT FILTER CAPACITOR DISCHARGE PROCEDURE (continued)  
4. Obtain a high resistance and high wattage  
resistor (25-1000 ohms and 25 watts mini-  
mum). This resistor is not supplied with  
machine. NEVER USE A SHORTING STRAP  
FOR THIS PROCEDURE.  
WARNING  
ELECTRIC SHOCK can kill.  
• Have an electrician install and  
service this equipment.  
5. Locate the four capacitor terminals (large  
hex head cap screws) shown in Figure F.1.  
At the bottom of the PowerBoard  
• Turn the input power off at the  
fuse box before working on  
equipment.  
(203,206)(207,202)  
• Do not touch electrically hot parts.  
6. Use electrically insulated gloves and insu-  
lated pliers. Hold the body of the resistor  
and connect the resistor leads across the  
two capacitor terminals. Hold the resistor in  
place for 10 seconds. DO NOT TOUCH  
CAPACITOR TERMINALS WITH YOUR  
BARE HANDS.  
• Prior to performing preventative mainte-  
nance, perform the following capacitor dis-  
charge procedure to avoid electric shock.  
DISCHARGE PROCEDURE  
7. Repeat the discharge procedure for the  
capacitor on the other two terminals.  
1. Turn off input power and disconnect input  
power lines.  
8. Check the voltage across the terminals of  
all capacitors with a DC voltmeter. Polarity  
of the capacitor terminals is marked on the  
PC board above the terminals. Voltage  
should be zero. If any voltage remains,  
repeat this capacitor discharge procedure.  
2. Remove the 5/16" hex head screws from  
the wraparound machine cover.  
3. Be careful not to make contact with the  
capacitor terminals located at the bottom of  
the Input Power Board.  
FIGURE F.1 – LOCATION OF INPUT FILTER CAPACITOR TERMINALS  
POWER  
BOARD  
CAPACITOR  
TERMINALS  
POWER  
RESISTOR  
RIGHT SIDE OF MACHINE  
INSULATED  
PLIERS  
INSULATED  
GLOVES  
PRO-CUT 80  
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F-12  
F-12  
TROUBLESHOOTING & REPAIR  
INPUT RECTIFIER TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained person-  
nel. Unauthorized repairs performed on this equipment may result in danger to the tech-  
nician or machine operator and will invalidate your factory warranty. For your safety and  
to avoid electrical shock, please observe all safety notes and precautions detailed  
throughout this manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
DESCRIPTION  
This test will help determine if the input rectifier has “shorted” or “open” diodes.  
MATERIALS NEEDED  
Analog voltmeter/ohmmeter (multimeter)  
Phillips head screw driver  
Wiring diagram  
This procedure takes approximately 15 minutes to perform.  
PRO-CUT 80  
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F-13  
F-13  
TROUBLESHOOTING & REPAIR  
INPUT RECTIFIER TEST (continued)  
4. With the phillips head screw driver, remove  
TEST PROCEDURE  
leads #207, 207A and #209 from the rectifi-  
er.  
1. Remove main input power to the machine.  
2. Perform the Input Filter Capacitor  
Discharge Procedure detailed earlier in  
this section.  
5. Use the analog ohmmeter to perform the  
tests detailed in Table F.1. See the Wiring  
Diagram.  
3. Locate the input rectifier (D1) and lead loca-  
tions. See Figure F.2. Carefully remove the  
silicone sealant from leads #207, #207A,  
and #209.  
FIGURE F.2 – INPUT RECTIFIER AND LEADS  
C
#207A  
B
#207  
A
#209  
TOP VIEW  
PRO-CUT 80  
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F-14  
F-14  
TROUBLESHOOTING & REPAIR  
INPUT RECTIFIER TEST (continued)  
TABLE F.1 INPUT RECTIFIER TEST POINTS  
TEST POINT TERMINALS  
ANALOG METER X10 RANGE  
+Probe  
- Probe  
Acceptable Meter Readings  
Greater than 1000 ohms  
Greater than 1000 ohms  
Greater than 1000 ohms  
A
B
C
207  
207  
207  
A
B
C
Greater than 1000 ohms  
Greater than 1000 ohms  
Greater than 1000 ohms  
207A  
207A  
207A  
A
B
C
Less than 100 ohms  
Less than 100 ohms  
Less than 100 ohms  
209  
209  
209  
207  
207  
207  
Less than 100 ohms  
Less than 100 ohms  
Less than 100 ohms  
A
B
C
207A  
207A  
207A  
Less than 100 ohms  
Less than 100 ohms  
Less than 100 ohms  
A
B
C
209  
209  
209  
Greater than 1000 ohms  
Greater than 1000 ohms  
Greater than 1000 ohms  
A
B
C
6. If the input rectifier does not meet the accept-  
able readings outlined in Table F.1, the com-  
ponent may be faulty. Replace.  
7. If the input rectifier is good, be sure to recon-  
nect leads #207, #207A and #209 to the cor-  
rect terminals and torque to 31 in.-lbs. Apply  
a coating of Essex D-4-8 insulating com-  
pound and Dow Corning 738 Silicone  
Sealant.  
NOTE: Before replacing the input rectifier (D1)  
check the input power switch (S1) and  
perform the Primary Power Board  
Resistance Test. Also check for leaky  
or faulty filter capacitors.  
8. If the input rectifier is faulty, see the Input  
Rectifier Bridge Removal & Replacement  
procedure. See the Wiring Diagram and  
Figure F.2.  
PRO-CUT 80  
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F-15  
F-15  
TROUBLESHOOTING & REPAIR  
PRIMARY POWER BOARD RESISTANCE TEST AND  
CAPACITOR VOLTAGE TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician or  
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manu-  
al.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
DESCRIPTION  
This test will determine if the primary power board has any “shorted” or “leaky” power diodes  
or Insulated Gate Bipolar Transistors (IGBTs). Also it will help to indicate any “shorted” input  
filter capacitors.  
MATERIALS NEEDED  
Analog voltmeter/ohmmeter (multimeter)  
Wiring Diagram  
7/16” Wrench  
This procedure takes approximately 25 minutes to perform.  
PRO-CUT 80  
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F-16  
F-16  
TROUBLESHOOTING & REPAIR  
PRIMARY POWER BOARD RESISTANCE TEST AND  
CAPACITOR VOLTAGE TEST (continued)  
FIGURE F.3 – PRIMARY POWER BOARD REMOVAL  
Primary power  
board with input  
filter capacitors  
204  
201  
205  
208  
+
+
207 202  
203 206  
CAPACITOR (C1) CAPACITOR (C2)  
TERMINALS  
TERMINALS  
TEST PROCEDURE  
1. Remove main input power to the PRO-  
CUT 80.  
4. Carefully remove the main transformer pri-  
mary leads #201, #204, #205 and #208  
from the power board.  
2. Perform the Input Filter Capacitor  
Discharge Procedure detailed earlier in  
this section.  
5. Use the analog ohmmeter to perform the  
test outlined in Table F.2.  
3. Locate the primary power board and asso-  
ciated lead locations. See Figure F.3.  
PRO-CUT 80  
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F-17  
F-17  
TROUBLESHOOTING & REPAIR  
PRIMARY POWER BOARD RESISTANCE TEST AND  
CAPACITOR VOLTAGE TEST (continued)  
TABLE F.2  
PRIMARY POWER BOARD RESISTANCE TEST POINTS  
TEST POINT TERMINALS  
ANALOG METER X10 RANGE  
+ Probe  
- Probe  
Acceptable Meter Readings  
201  
207A  
207A  
201  
Greater than 1000 ohms  
Less than 100 ohms  
204  
207A  
207A  
204  
Greater than 1000 ohms  
Less than 100 ohms  
202A  
204  
204  
202A  
Greater than 1000 ohms  
Less than 100 ohms  
202A  
201  
201  
202A  
Greater than 1000 ohms  
Less than 100 ohms  
205  
203A  
203A  
205  
Greater than 1000 ohms  
Less than 100 ohms  
208  
203A  
203A  
208  
Greater than 1000 ohms  
Less than 100 ohms  
206  
208  
208  
206  
Greater than 1000 ohms  
Less than 100 ohms  
206  
205  
205  
206  
Greater than 1000 ohms  
Less than 100 ohms  
6. If the power board does not meet the  
acceptable readings outlined in Table F.2,  
the board is faulty. Replace. See Power  
Board Removal and Replacement  
Procedure.  
7. If the power board “passes” the resistance  
test, the IGBT portion of the board is good.  
However, other circuits on the power board  
may be faulty. These circuits are NOT readi-  
ly tested or serviceable.  
NOTE: Complete power board and filter  
capacitor replacement is recom-  
mended.  
8. Carefully reconnect leads #201, #204, #205,  
and #208 to their appropriate terminals.  
Torque To 75 IN. LBS.  
PRO-CUT 80  
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F-18  
F-18  
TROUBLESHOOTING & REPAIR  
PRIMARY POWER BOARD RESISTANCE TEST AND  
CAPACITOR VOLTAGE TEST (continued)  
4. The following tests will be performed with  
the input power applied to the PRO-CUT  
80. BE CAREFUL. ALWAYS REMOVE  
THE INPUT POWER AND PERFORM THE  
INPUT FILTER CAPACITOR DISCHARGE  
PROCEDURE BEFORE TOUCHING ANY  
MACHINE COMPONENT.  
CAPACITOR VOLTAGE TEST  
This test will help the technician to determine if  
the input filter capacitors are being charged  
equally to the correct voltage levels.  
NOTE: This test should only be conducted with  
the PRO-CUT 80 connected for 400 VAC or  
above, and with the appropriate input voltage  
applied.  
WARNING  
ELECTRIC SHOCK can kill.  
TEST PROCEDURE  
• Have an electrician install and  
service this equipment.  
1. Remove main input power to the PRO-CUT  
80.  
• Turn the input power off at the  
fuse box before working on  
equipment.  
2. Perform the Input Filter Capacitor  
Discharge Procedure detailed earlier in  
this section.  
• Do not touch electrically hot parts.  
3. Locate and familiarize yourself with the  
capacitor test locations on the primary  
power board. See Figure F.3.  
†
5. Apply the correct input power and turn ON  
the PRO-CUT 80.  
†
NOTE: This test should only be conducted  
with the PRO-CUT 80 reconnect  
switch and “A” jumper configured for  
400 VAC and above.  
PRO-CUT 80  
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F-19  
F-19  
TROUBLESHOOTING & REPAIR  
PRIMARY POWER BOARD RESISTANCE TEST AND  
CAPACITOR VOLTAGE TEST (continued)  
6. Check for the appropriate voltages outlined  
in Table F.3.  
7. If the test voltages do not meet the expect-  
ed values as listed in Table F.3, the capaci-  
tors or other components on the power  
board may be faulty. Replace.  
NOTE: Voltages may vary with the input line  
voltage.  
NOTE: If the capacitor voltages are NOT bal-  
anced within 20 VDC, the capacitors may need  
“conditioning.” See the Maintenance section.  
NOTE: If the capacitor voltage is too high  
(over 400 VDC) or too low (less than 220  
VDC) the control board will deactivate relay  
CR1 + CR2. This will prevent output.  
TABLE F.3 - CAPACITOR VOLTAGES  
EXPECTED VOLTS  
DC AT CAPACITOR  
TERMINALS  
INPUT APPLIED  
460VAC  
440VAC  
415VAC  
380VAC  
325VDC  
311VDC  
293VDC  
269VDC  
NOTE: If Capacitor C1 is found to be defective, both Capacitors C1 and C2 must be replaced  
at the same time. The capacitors must be replaced in matched sets.  
PRO-CUT 80  
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F-20  
F-20  
TROUBLESHOOTING & REPAIR  
OUTPUT POWER BOARD RESISTANCE TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician or  
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manu-  
al.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
DESCRIPTION  
This test will help the technician determine if the output power board is faulty.  
MATERIALS NEEDED  
5/16” Nut driver  
Analog Volt/ohmmeter  
7/16” Wrench  
This procedure takes approximately 18 minutes to perform.  
PRO-CUT 80  
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F-21  
F-21  
TROUBLESHOOTING & REPAIR  
OUTPUT POWER BOARD RESISTANCE TEST (continued)  
FIGURE F.4 – OUTPUT POWER BOARD LEAD LOCATIONS  
G3439 PRO-CUT 80 OUTPUT  
+
X4  
X2  
(B12)  
(B11)  
TEST POINT  
LED3  
D25  
LED5  
(B21)  
LED1  
LED4  
LED2  
TEST POINT  
D29  
X20  
X40  
J33  
J31  
J34  
J32  
J30  
TEST PROCEDURE  
1. Remove input power to the PRO-CUT 80  
machine.  
4. Carefully remove leads X4, X2, B21, X20, X40  
and plugs J33 and J32 from the output  
power board. See Figure F.4.  
2. Perform the Input Filter Capacitor  
Discharge Procedure detailed earlier in this  
section.  
5. Using the analog ohmmeter, perform the  
resistance checks per Table F.4.  
3. Remove the torch assembly from the  
machine.  
PRO-CUT 80  
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F-22  
F-22  
TROUBLESHOOTING & REPAIR  
OUTPUT POWER BOARD RESISTANCE TEST (continued)  
TABLE F.4 - OUTPUT POWER BOARD RESISTANCE  
CIRCUIT OR  
COMPONENT(S)  
BEING TESTED  
TEST POINTS  
EXPECTED RESISTANCE  
+Probe J33-Pin4  
to  
–Probe Terminal X2  
Diode A1  
and  
associated trace  
Less than  
100 ohms  
+Probe Terminal X2  
to  
–Probe J33-Pin4  
Diode A1  
and  
associated trace  
Greater than  
1000 ohms  
+Probe J33-Pin4  
to  
–Probe Terminal X4  
Diode A1  
and  
associated trace  
Less than  
100 ohms  
+Probe Terminal X4  
to  
–Probe J33-Pin4  
Diode A1  
and  
associated trace  
Greater than  
1000 ohms  
+Probe D29 Test Point  
to  
–Probe Terminal X20  
Diode A2  
and  
associated trace  
Less than  
100 ohms  
+Probe Terminal X20  
to  
–Probe D29 Test Point  
Diode A2  
and  
associated trace  
Greater than  
1000 ohms  
+Probe D29 Test Point  
to  
-Probe Terminal X40  
Diode A2  
and  
associated trace  
Less than  
100 ohms  
+Probe Terminal X40  
to  
–Probe D29 Test Point  
Diode A2  
and  
associated trace  
Greater than  
1000 ohms  
+Probe D29 Test Point  
to  
–Probe J32-Pin14  
Transistor A2  
and  
associated trace  
Less than  
100 ohms  
+Probe J32-Pin14  
to  
–Probe D29 Test Point  
Transistor A2  
and  
associated trace  
Greater than  
1000 ohms  
6. If any of the resistance checks are not correct, the  
output power board is faulty. Replace. See the  
Output Power Board Removal and Replacement  
Procedure.  
8. Carefully reconnect the leads and plugs previously  
removed. Torque X2, X4, and B21 to 75 IN. LBS.  
7. If the output power board “passes” the resistance  
test, the power diode and transistor portion of the  
board is good. However, other circuits on the  
power board may be faulty. These circuits are NOT  
readily tested or serviceable.  
PRO-CUT 80  
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F-23  
F-23  
TROUBLESHOOTING & REPAIR  
TORCH CONTINUITY AND SOLENOID TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician or  
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manu-  
al.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
DESCRIPTION  
This procedure will help the technician determine if the torch cable, consumables and elec-  
trode solenoid are functioning properly.  
MATERIALS NEEDED  
Volt/ohmmeter  
12 VDC @ 1 Amp Power Supply  
This procedure takes approximately 15 minutes to perform.  
PRO-CUT 80  
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F-24  
F-24  
TROUBLESHOOTING & REPAIR  
TORCH CONTINUITY AND SOLENOID TEST (continued)  
FIGURE F.5 - TORCH CONNECTOR - MACHINE END  
8
7
3
9
6
5
1
4
2
3. Using the ohmmeter, check the torch resis-  
tances per Table F.5.  
TEST PROCEDURE  
1. Remove input power to the PRO-CUT 80  
machine.  
NOTE: Take the “Pin” test point measurements  
at the machine end of the torch assem-  
bly. See Figure F.5.  
2. Remove the torch assembly from the  
machine.  
TABLE F.5 - TORCH ASSEMBLY RESISTANCES  
CIRCUIT(S) BEING EXPECTED  
TESTED RESISTANCE  
TEST  
POINTS  
TEST  
CONDITIONS  
Pin 7 to Pin 8  
Parallel pilot arc  
leads  
1.5 ohms maximum  
1.0 ohm maximum  
1.0 ohm maximum  
100K ohms minimum  
1.0 ohm maximum  
None  
Pin 7 to Torch  
Nozzle  
One pilot arc lead to  
nozzle  
Torch consumables  
in place  
Pin 8 to Torch  
Nozzle  
One pilot arc lead to  
nozzle  
Torch consumables  
in place  
Pin 1 to Pin 9  
Pin 1 to Pin 9  
Pin 2 to Pin 3  
Torch trigger circuit  
Torch trigger circuit  
Electrode Solenoid  
Torch trigger NOT  
pulled (not activated)  
Torch trigger pulled  
(activated)  
45 to 55 ohms  
None  
Pin 7 to Torch  
Electrode at machine  
end of torch  
Pilot and Electrode  
circuit  
1.0 ohm maximum  
Torch consumables  
in place  
Pin 8 to Torch  
Electrode at machine  
end of torch  
Pilot and Electrode  
circuit  
1.0 ohm maximum  
Torch consumables  
in place  
4. If any of the resistance checks are not cor-  
rect, the torch assembly may be faulty.  
Repair or replace.  
5. Carefully apply the 12 VDC supply to the  
electrode solenoid. (positive to Pin 2 and  
negative to Pin 3). The electrode solenoid  
should activate. Listen for the solenoid  
action in the torch handle. If the solenoid  
does not activate, it may be faulty. Replace.  
PRO-CUT 80  
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F-25  
F-25  
TROUBLESHOOTING & REPAIR  
AIR/GAS SOLENOID TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician or  
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manu-  
al.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
DESCRIPTION  
This procedure will help the technician determine if the solenoid is functioning properly.  
MATERIALS NEEDED  
5/16” Nut driver  
12 VDC @ 3 amp supply  
Volt/ohmmeter  
This procedure takes approximately 13 minutes to perform.  
PRO-CUT 80  
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F-26  
F-26  
TROUBLESHOOTING & REPAIR  
AIR/GAS SOLENOID TEST (continued)  
FIGURE F.6 – AIR SOLENOID  
TEST PROCEDURE  
1. Remove input power to the machine.  
See the Wiring Diagram. If the leads are  
good, the solenoid coil may be faulty.  
2. Perform the Input Capacitor Discharge  
Procedure detailed earlier in this section.  
6. Carefully apply the 12 VDC supply to the  
solenoid leads at plug J31 (positive to J31  
pin-6 lead #366 and negative to J31 pin-5  
lead #361).  
3. Locate the air solenoid and leads. See Figure  
F.6.  
4. Carefully remove plug J31 from the output  
power board. See Figure F.7.  
With proper air pressure applied, the sole-  
noid should activate and air should flow.  
5. Check the coil resistance of the solenoid at  
plug J31 pin-6 to J31 pin-5. Normal resis-  
tance is approximately 20 ohms. If the resis-  
tance is abnormal, check the continuity (zero  
or very low resistance) of leads #366 and  
#361 between the solenoid and plug J31.  
If the solenoid activates but air does not  
flow, check for a restriction in the air line.  
7. Install plug J31 back into the output power  
board.  
FIGURE F.7 – PLUG J31 LOCATION  
G3439 PRO-CUT 80 OUTPUT  
+
X4  
X2  
(B12)  
(B11)  
TEST POINT  
LED3  
D25  
LED5  
(B21)  
LED1  
LED4  
LED2  
TEST POINT  
D29  
X20  
X40  
J33  
J31  
J34  
J32  
J30  
PRO-CUT 80  
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F-27  
F-27  
TROUBLESHOOTING & REPAIR  
(T2) AUXILIARY TRANSFORMER TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician or  
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manu-  
al.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
DESCRIPTION  
The test will determine if the auxiliary transformer is functional when the correct primary volt-  
age is applied to the primary winding.  
MATERIALS NEEDED  
Volt/ohmmeter  
Machine wiring diagram  
5/16” Nut driver  
230 VAC isolated power supply  
This procedure takes approximately 18 minutes to perform.  
PRO-CUT 80  
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F-28  
F-28  
TROUBLESHOOTING & REPAIR  
(T2) AUXILIARY TRANSFORMER TEST (continued)  
FIGURE F.8 – T2 AUXILIARY TRANSFORMER  
10 PIN  
D1  
6 1  
7
2
3
AUXILIARY  
TRANSFORMER  
8
9
4
5
Plug J21  
8 PIN  
H2  
5
1
2
H3  
H6  
H4  
H5  
7
8
4
Plug 22  
PROCEDURE  
1. Remove main input power to the PRO-CUT  
80 machine.  
5. Carefully apply the 230 VAC isolated supply  
to leads H1 located at the D1 input bridge  
(see wiring diagram) and H3 (2J22) of the  
auxiliary transformer.  
2. Perform the Input Filter Capacitor  
Discharge Procedure detailed earlier in this  
section.  
6. Carefully check for the presence of the fol-  
lowing primary and secondary voltages at the  
appropriate leads at plugs J21 and J22. See  
Figure F.8 and Table F.6..  
3. Locate the auxiliary transformer. See Fig. F.8  
4. Locate and disconnect plugs J21 and J22  
from the wiring harness. Cut any necessary  
cable ties. See Figure F.8.  
PRO-CUT 80  
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F-29  
F-29  
TROUBLESHOOTING & REPAIR  
(T2) AUXILIARY TRANSFORMER TEST (continued)  
TABLE F.6 - J21 AND J22 VOLTAGES  
TEST POINT  
H1  
TEST POINT  
H2 (5J22)  
H4 (7J22)  
EXPECTED VOLTAGE  
200 - 208VAC  
380 - 415VAC  
440 - 460VAC  
12VAC  
H1  
H1  
H5 (8J22)  
Brown (8J21)  
Red (2J21)  
Blue (9J21)  
Blue (4J21)  
Yellow (1J21)  
Brown (3J21)  
Red (6J21)  
White (5J21)  
White (5J21)  
Yellow (7J21)  
24VAC  
18VAC  
18VAC  
115VAC  
7. If the correct test voltages are present, the  
auxiliary transformer is good.  
9. If the auxiliary transformer tests good but it  
does not function when connected to the  
PRO-CUT 80, check the harness wiring to  
the auxiliary transformer. See the Wiring  
Diagram.  
8. If any of the voltages are missing or very low  
with the proper primary voltage applied, the  
auxiliary transformer may be faulty.  
10. When finished with the test, replace plugs  
21 and 22 and the case wraparound.  
PRO-CUT 80  
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F-30  
F-30  
TROUBLESHOOTING & REPAIR  
TRIGGER CIRCUIT TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician or  
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manu-  
al.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
DESCRIPTION  
The procedure will help the technician determine if there is a problem or “fault” in the inter-  
nal trigger circuit.  
MATERIALS NEEDED  
Ohmmeter/voltmeter (multimeter)  
5/16” Nut driver  
Simplified Trigger Circuit Diagram  
This procedure takes approximately 19 minutes to perform.  
PRO-CUT 80  
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F-31  
F-31  
TROUBLESHOOTING & REPAIR  
TRIGGER CIRCUIT TEST (continued)  
FIGURE F.9 – SIMPLIFIED TRIGGER CIRCUIT DIAGRAM  
SIMPLIFIED TRIGGER CIRCUIT  
OUTPUT BOARD  
CONTROL BOARD  
+17VDC  
+15VDC  
TORCH  
RECEPTACLE  
P
R
O
C
E
S
S
O
R
#4  
#2  
1J31  
2J31  
9
1
TRIGGER SWITCH  
IN TORCH HANDLE  
#344  
#312  
3J32  
11J3  
14J32  
12J3  
D25  
AUX  
COM  
COM  
7. If the correct voltage is present in Step 6,  
carefully check for the presence of approxi-  
mately 15 VDC from plug J32 pin-3  
(lead#354) (positive) to plug J32 pin-14  
(lead#312) (negative). See Figure F.10. Also  
see Control Board LED Definitions and  
related figures. If the correct voltage is not  
present, perform the Low Voltage Circuit  
Test.  
PROCEDURE  
1. Remove input power to the PRO-CUT 80  
machine.  
2. Perform the Input Filter Capacitor  
Discharge Procedure detailed earlier in this  
section.  
3. Locate the torch cable receptacle and leads  
#2 and #4. See Figure F.9, the Simplified  
Trigger Circuit Diagram. These leads are best  
accessed at plug J31 on the output board.  
See Figure F.10.  
8. If the correct voltage is present in the above  
test, carefully pull the torch trigger.  
4. Using the ohmmeter, check for continuity  
(less than one ohm) from lead #2 to lead #4.  
The torch trigger must be pulled and all input  
power removed from the machine. If conti-  
nuity (less than one ohm) is not read, check  
the leads from plug J31 to the torch cable  
receptacle. Perform the Torch Continuity  
and Solenoid Test.  
WARNING  
PILOT ARC, CUTTING ARC, AND HIGH VOLT-  
AGE MAY BE PRESENT AT THE  
TORCH HEAD. Perform this test  
with the air input removed to avoid  
a pilot arc at the torch.  
5. If less than one ohm is read (only when the  
torch trigger is pulled), proceed to the next  
step.  
Also see Output Board LED  
Definitions and related figures.  
6. Apply the correct input power to the PRO-  
CUT 80. Carefully check for approximately  
17 VDC from plug J31 pin-1(lead#4) (positive)  
to plug J31 pin-2 (lead#2) (negative). See  
Figure F.10. If the correct voltage is not pre-  
sent, perform the Low Voltage Circuit Test.  
Also see Output Board LED Definitions and  
related figures.  
PRO-CUT 80  
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F-32  
F-32  
TROUBLESHOOTING & REPAIR  
TRIGGER CIRCUIT TEST (continued)  
9. With the torch trigger activated check the  
voltage at plug J32 pin-3 (lead#354) (posi-  
tive) to plug J32 pin-14 (lead#312) (nega-  
tive). Normal is less than 1 VDC. If more  
than 1 VDC is indicated, the power output  
board may be faulty. Release (deactivate)  
the torch trigger and remove input power to  
the PRO-CUT 80.  
10. Perform the Input Filter Capacitor  
Discharge Procedure.  
11. Check the continuity of leads #354 and  
#312 between the output board and the  
control board.  
See Figure F.9, the  
Simplified Trigger Circuit Diagram, and  
Figure F.10.  
12. If all of the above checks are OK, the con-  
trol board may be faulty. Replace.  
PRO-CUT 80  
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F-33  
F-33  
TROUBLESHOOTING & REPAIR  
TRIGGER CIRCUIT TEST (continued)  
FIGURE F.10 - OUTPUT BOARD TRIGGER CIRCUIT TEST POINTS AND LEDS  
G3439 PRO-CUT 80 OUTPUT  
+
X4  
X2  
(B12)  
(B11)  
TEST POINT  
LED3  
D25  
LED5  
(B21)  
LED1  
LED4  
LED2  
TEST POINT  
D29  
X20  
X40  
J33  
J31  
J34  
J32  
J30  
PRO-CUT 80 OUTPUT BOARD  
LED DEFINITIONS  
LED4: (Green) This light indicates that the trig-  
ger circuit on the output board has been activat-  
ed. This LED should be lit when the torch or  
remote trigger is closed. This trigger circuit, on  
the output board, then sends a signal to the  
control board.  
LED1: (Red) This light indicates that 24 VAC is  
being supplied to the output board from the aux-  
iliary transformer. It also shows that the 24 VAC  
is being rectified to approximately 32 VDC. This  
DC voltage is used for the "parts-in-place"  
check for the torch circuit.  
LED5: (Green) This light indicates that the elec-  
trode solenoid driver circuit is functioning. When  
this light is lit, the electrode solenoid should be  
activated. The electrode solenoid should be  
energized during gas (air) pre-flow time. During  
pilot and cutting arc periods, the LED should be  
off. When the arc goes out, the machine enters  
the post-flow state. Two seconds after the start  
of post-flow the electrode solenoid is activated a  
few times. The LED should blink to indicate this  
activity. The electrode solenoid will then be  
energized for the duration of post-flow. (The LED  
should be on.)  
LED2: (Red) This light indicates that 12 VAC is  
being supplied to the output board from the aux-  
iliary transformer. It also shows that the 12 VAC  
is being rectified to approximately 17 VDC. This  
DC voltage is used to power the trigger circuit  
and solenoid driver circuits incorporated on the  
output board.  
LED3: (Green) This light indicates that the air  
solenoid driver circuit is functioning. When this  
LED is lit, the air solenoid should be activated.  
PRO-CUT 80  
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F-34  
F-34  
TROUBLESHOOTING & REPAIR  
TRIGGER CIRCUIT TEST (continued)  
FIGURE F.11 - CONTROL BOARD LEDs  
P
R
O-CU  
T
8
0
C
ON  
T
R
O
L
G3443  
LED2  
LED1  
LED3  
CONTROL BOARD LED DEFINITIONS  
LED1: (Red) This light indicates that 18 VAC is  
being supplied to the control board from the  
auxiliary transformer. It also shows that the 18  
VAC is being rectified and should be regulated to  
+15 VDC. This +15 VDC supply is used to power  
the circuitry on the control board.  
LED2: (Red) This light indicates that the +5.5  
VDC is present. This voltage is derived from the  
+15 VDC supply. The +5.5 VDC supply is used  
to power the circuitry on the control board.  
LED3: (Red) This light indicates that 18 VAC is  
being supplied to the control board from the  
auxiliary transformer. It also shows that the 18  
VAC is being rectified and should be regulated to  
-15 VDC. This -15 VDC supply is used to power  
the circuitry on the control board.  
PRO-CUT 80  
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F-35  
F-35  
TROUBLESHOOTING & REPAIR  
LOW VOLTAGE CIRCUIT TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician or  
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manu-  
al.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
DESCRIPTION  
These voltage checks will help the technician determine if the correct voltages are being  
applied and processed by the various P.C. boards. Some of the voltage verification test  
points are not easily accessible. The presence of these voltages can also be confirmed by  
LEDs on the various P.C. boards.  
MATERIALS NEEDED  
5/16” Nut driver  
Volt/ohmmeter (multimeter)  
This procedure takes approximately 20 minutes to perform.  
PRO-CUT 80  
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F-36  
F-36  
TROUBLESHOOTING & REPAIR  
LOW VOLTAGE CIRCUIT TEST (continued)  
FIGURE F.12 - LOW VOLTAGE CIRCUIT DIAGRAM  
T2 AUXILIARY  
TRANSFORMER  
TO H1  
"C" TERMINAL  
INPUT  
H1  
BROWN  
BROWN  
#53  
#56  
8
3
3J30  
=
RECTIFIER  
17 VDC  
12VAC  
24VAC  
6J30  
PLASMA  
OUTPUT  
BOARD  
H2  
RED  
RED  
#51  
#54  
2
6
1J30  
=232VDC  
4J30  
H3  
H4  
H5  
TO  
RECONNECT  
LEAD "A"  
D
I
BLUE  
WHITE  
BLUE  
#61  
#62  
#64  
4
5
1J1  
=+15VDC  
#216  
#219  
6J2  
9J2  
15J40  
10J40  
B
18VAC  
18VAC  
+
S
P
L
A
Y
O
A
R
D
2J1  
=-15VDC  
4J1  
+15VDC  
CONTROL BOARD  
9
J21  
PROCEDURE  
1. Remove input power to the PRO-CUT 80  
machine.  
5. Check for the presence of 17 VDC on the out-  
put board.  
2. Using the 5/16" nutdriver remove the case  
wraparound cover.  
a. LED2 should be lit when 17 VDC is present.  
See Figure F.13. See Output Board LED  
Definitions and Figure F.12, Low Voltage  
Circuit Diagram.  
WARNING  
b. To verify the presence of 17 VDC, check  
from plug J31 Pin-6 to diode D25 (anode).  
See Figure F.13. Make certain the volt-  
meter probes make good contact with pin-  
6 and the diode anode lead. It will be nec-  
essary to penetrate the silicon sealant.  
ELECTRIC SHOCK can kill.  
• Do not touch electrically hot parts.  
6. Check for the presence of +15 VDC on the  
control board.  
a. LED1 should be lit when +15 VDC is pre-  
sent. See Figure F.13. See Control  
Board LED Definitions and Figure F.12,  
Low Voltage Circuit Diagram.  
3. Apply the correct input power to the machine  
and carefully check for the following voltages.  
4. Check for the presence of approximately 32  
VDC on the output board.  
7. Check for the presence of -15 VDC on the con-  
trol board.  
a. LED1 should be lit when 32 VDC is present.  
See Figure F.13. See Output Board LED  
Definitions and Figure F.12, Low Voltage  
Circuit Diagram.  
a. LED3 should be lit when -15 VDC is pre-  
sent. See Figure F.13. See Control Board  
LED Definitions and Figure F.12, Low  
Voltage Circuit Diagram.  
b. To verify the presence of 32 VDC, check  
across capacitor C13. Make certain the  
voltmeter probes make good contact with  
the capacitor leads. See Figure F.13.  
PRO-CUT 80  
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F-37  
F-37  
TROUBLESHOOTING & REPAIR  
8. Check for the presence of +5 VDC on the  
control board.  
a. LED2 should be lit when +5 VDC is pre-  
sent. See Figure F.14. See Control Board  
LED Definitions and Figure F.12, Low  
Voltage Circuit Diagram.  
9. Check for the presence of +15 VDC being  
applied to the display board from the control  
board. You may have to remove the display  
board to check it.  
a. +15 VDC should be present at leads  
#216(+) to #219(-). See Figure F.15 and  
Figure F.12, Low Voltage Circuit  
Diagram.  
10. If any of the DC supply voltages are incorrect  
or missing, make certain the correct AC sup-  
ply voltages are being applied to the P.C.  
boards. See Figure F.12, Low Voltage  
Circuit Diagram and (T2) Auxiliary  
Transformer Test.  
11. When the test is complete, remove input  
power and replace the case wraparound cover.  
PRO-CUT 80  
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F-38  
F-38  
TROUBLESHOOTING & REPAIR  
LOW VOLTAGE CIRCUIT TEST (continued)  
FIGURE F.13 – OUTBOARD LOW VOLTAGE CIRCUIT TEST POINTS AND LEDs  
G3439 PRO-CUT 80 OUTPUT  
+
X4  
X2  
(B12)  
(B11)  
TEST POINT  
LED3  
D25  
LED5  
(B21)  
LED1  
LED4  
LED2  
TEST POINT  
D29  
X20  
X40  
J33  
J31  
J34  
J32  
J30  
PRO-CUT 80 OUTPUT BOARD  
LED DEFINITIONS  
LED4: (Green) This light indicates that the trig-  
ger circuit on the output board has been acti-  
vated. This LED should be lit when the torch or  
remote trigger is closed. This trigger circuit, on  
the output board, then sends a signal to the  
control board.  
LED1: (Red) This light indicates that 24 VAC is  
being supplied to the output board from the aux-  
iliary transformer. It also shows that the 24 VAC  
is being rectified to approximately 28 VDC. This  
DC voltage is used for the "parts-in-place"  
check for the torch circuit.  
LED5: (Green) This light indicates that the elec-  
trode solenoid driver circuit is functioning. When  
this light is lit, the electrode solenoid should be  
activated. The electrode solenoid should be  
energized during gas (air) pre-flow time. During  
pilot and cutting arc periods, the LED should be  
off. When the arc goes out, the machine enters  
the post-flow state. Two seconds after the start  
of post-flow the electrode solenoid is activated a  
few times. The LED should blink to indicate this  
activity. The electrode solenoid will then be  
energized for the duration of post-flow. (The LED  
should be on).  
LED2: (Red) This light indicates that 12 VAC is  
being supplied to the output board from the aux-  
iliary transformer. It also shows that the 12 VAC  
is being rectified to approximately 17 VDC. This  
DC voltage is used to power the trigger circuit  
and solenoid driver circuits incorporated on the  
output board.  
LED3: (Green) This light indicates that the air  
solenoid driver circuit is functioning. When this  
LED is lit, the air solenoid should be activated.  
PRO-CUT 80  
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F-39  
F-39  
TROUBLESHOOTING & REPAIR  
LOW VOLTAGE CIRCUIT TEST (continued)  
FIGURE F.14 – CONTROL BOARD LEDs  
PRO-CUT 80 CONTROL G3443  
LED2  
LED1  
LED3  
CONTROL BOARD LED DEFINITIONS  
LED2: (Red) This light indicates that the +5.5  
VDC is present. This voltage is derived from the  
+15 VDC supply. The +5.5 VDC supply is used  
to power the circuitry on the control board.  
LED1: (Red) This light indicates that 18 VAC is  
being supplied to the control board from the  
auxiliary transformer. It also shows that the 18  
VAC is being rectified and should be regulated to  
+15 VDC. This +15 VDC supply is used to power  
the circuitry on the control board.  
LED3: (Red) This light indicates that 18 VAC is  
being supplied to the control board from the  
auxiliary transformer. It also shows that the 18  
VAC is being rectified and should be regulated to  
-15 VDC. This 15 VDC supply is used to power  
the circuitry on the control board.  
FIGURE F.15 – DISPLAY BOARD TEST POINTS  
L10721 DISPLAY BOARD  
(REAR VIEW)  
J 40  
1
15  
#216  
#219  
PRO-CUT 80  
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F-40  
F-40  
TROUBLESHOOTING & REPAIR  
CONTROL BOARD REMOVAL AND REPLACEMENT  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician or  
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manu-  
al.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
DESCRIPTION  
The following procedure will aid the technician in removing the control board for maintenance  
or replacement.  
MATERIALS NEEDED  
5/16” Nut driver  
Needle-nose pliers  
This procedure takes approximately 15 minutes to perform.  
PRO-CUT 80  
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F-41  
F-41  
TROUBLESHOOTING & REPAIR  
CONTROL BOARD REMOVAL AND REPLACEMENT (continued)  
FIGURE F.16 - CASE FRONT SCREW REMOVAL  
4 Screws  
PROCEDURE  
1. Remove input power to the PRO-CUT 80  
machine.  
3. Using the 5/16” nut driver, remove the four  
screws holding the front assembly to the top  
and base of the machine. See Figure F.16.  
2. Remove the wraparound cover and perform  
the Input Filter Discharge Procedure  
detailed earlier in this section.  
4. Carefully slide (do not force) the front away  
from the rest of the machine about one inch.  
This will allow more “working” room to  
remove the control board.  
FIGURE F.17 - CONTROL BOARD MOLEX PLUG REMOVAL  
CONTROL  
BOARD  
MOLEX PLUGS (5)  
PRO-CUT 80  
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F-42  
F-42  
TROUBLESHOOTING & REPAIR  
CONTROL BOARD REMOVAL AND REPLACEMENT (continued)  
5. Locate the control board and the five molex  
6. Carefully remove the five molex type plugs by  
depressing the locking tabs and gently  
extracting the plugs from the P.C. board  
receptacles.  
type plugs connected to it. See Figure F.17.  
FIGURE F.18 - CONTROL BOARD REMOVAL FROM MOUNTING PINS  
DEPRESS  
LOCKING TAB ON  
MOUNTING PIN  
MOUNTING  
PIN (8)  
CONTROL  
BOARD  
7. Using the needle-nose pliers and screwdriv-  
er, gently remove the control board from the  
eight mounting pins by depressing the tabs  
on the mounting pins and carefully removing  
the board from the pins. See Figure F.18.  
9. Replace the five molex type plugs in their  
respective receptacles. Be certain they are  
securely in place.  
10. Carefully reposition the front assembly in  
place and install the four mounting screws  
previously removed.  
CAUTION  
11. Inspect, clear and secure all leads before  
installing the case wrap-around reassembly.  
Be sure to follow the recommended static-free  
methods for handling printed circuit boards.  
Failure to do so can result in permanent damage  
to the equipment.  
12. Using the 5/16” nut driver, install the case  
wraparound.  
8. When replacing the control board, align the  
mounting holes with the eight mounting pins  
and gently slide the P.C. board onto the  
mounting pins until the board “snaps” onto  
the pins.  
PRO-CUT 80  
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F-43  
F-43  
TROUBLESHOOTING & REPAIR  
DISPLAY BOARD REMOVAL AND REPLACEMENT  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician or  
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manu-  
al.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call or 1-800-833-9353 (WELD).  
DESCRIPTION  
The following procedure will aid the technician in removing the display board for maintenance  
or replacement.  
MATERIALS NEEDED  
5/16” Nut driver  
Screw driver  
This procedure takes approximately 15 minutes to perform.  
PRO-CUT 80  
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F-44  
F-44  
TROUBLESHOOTING & REPAIR  
DISPLAY BOARD REMOVAL & REPLACEMENT (continued)  
FIGURE F.19 - CASE FRONT SCREW REMOVAL  
4 Screws  
PROCEDURE  
1. Remove the input power to the PRO-CUT 80  
machine.  
4. Carefully slide (do not force) the front away  
from the rest of the machine about one inch.  
This will allow more “working” room to  
remove the display board.  
2. Remove the wraparound cover and perform  
the Input Filter Capacitor Discharge  
Procedure detailed earlier in this section.  
3. Using the 5/16” nut driver, remove the four  
screws holding the front assembly to the top  
and base of the machine. See Figure F.19.  
PRO-CUT 80  
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F-45  
F-45  
TROUBLESHOOTING & REPAIR  
DISPLAY BOARD REMOVAL & REPLACEMENT (continued)  
FIGURE F.20 – DISPLAY BOARD REMOVAL  
DISPLAY BOARD  
CASE FRONT  
5. Locate the display P.C. board and the one  
plug connected to it. See Figure F.20.  
8. When replacing the display board, carefully  
connect the plug into the board. Make cer-  
tain the plug is secure and the locking tab is  
in place.  
6. Gently remove the display P.C. board from  
the three mounting pins.  
9. Align the display board with the three  
mounting pins and slide the display board  
into place.  
CAUTION  
Be sure to follow the recommended static-free  
methods for handling printed circuit boards.  
Failure to do so can result in permanent damage  
to the equipment.  
10. Carefully reposition the front assembly in  
place and install the four mounting screws  
previously removed.  
11. Inspect, clear and secure all leads in prepa-  
ration for the case wraparound reassembly.  
7. Depress the locking tab and remove the plug  
connector from the display board.  
12. Using the 5/16” nut driver, install the case  
wraparound.  
PRO-CUT 80  
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F-46  
F-46  
TROUBLESHOOTING & REPAIR  
OUTPUT POWER BOARD REMOVAL AND REPLACEMENT  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician or  
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manu-  
al.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
DESCRIPTION  
The following procedure will aid the technician in removing the output power board for main-  
tenance or replacement.  
MATERIALS NEEDED  
5/16” Nut driver  
3/16” Allen type wrench  
7/16” Wrench  
Penetrox A-13 (Lincoln E2529) Electrical Joint Compound  
Phillips head screw driver  
Torque wrench  
This procedure takes approximately 25 minutes to perform.  
PRO-CUT 80  
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F-47  
F-47  
TROUBLESHOOTING & REPAIR  
OUTPUT POWER BOARD REMOVAL & REPLACEMENT (continued)  
FIGURE F.21 – OUTPUT POWER BOARD REMOVAL  
OUTPUT POWER BOARD  
PROCEDURE  
1. Remove input power to the PRO-CUT 80  
machine.  
3. Locate the output power P.C. board and  
associated lead and plug connections. See  
Figures F.21 and F.22.  
2. Remove the case wraparound and perform  
the Input Capacitor Filter Discharge  
Procedure detailed earlier in this section.  
PRO-CUT 80  
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F-48  
F-48  
TROUBLESHOOTING & REPAIR  
OUTPUT POWER BOARD REMOVAL & REPLACEMENT (continued)  
FIGURE F.22 – OUTPUT BOARD LEAD LOCATIONS  
G3439 PRO-CUT 80 OUTPUT  
+
X4  
X2  
(B12)  
(B11)  
TEST POINT  
LED3  
D25  
LED5  
(B21)  
LED1  
LED4  
LED2  
TEST POINT  
D29  
X20  
X40  
J33  
J31  
J34  
J32  
J30  
4. Using the 7/16” wrench, remove leads X4, X2  
and B21 from the output power board.  
9. Carefully remove the output power board  
from the heat sink.  
5. Remove plugs J30, J31, J32, J33, and J34  
from the output power board.  
CAUTION  
6. Remove leads X20 and X40 from the output  
power board.  
Be sure to follow the recommended static-free  
methods for handling printed circuit boards.  
Failure to do so can result in permanent damage  
to the equipment.  
7. Using the phillips head screw driver, remove  
the four screws from the lower + upper left  
and right corners of the output power board.  
8. Using the 3/16” allen head wrench, remove  
the four socket screws mounting the output  
power board to the heat sink.  
PRO-CUT 80  
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F-49  
F-49  
TROUBLESHOOTING & REPAIR  
REPLACEMENT PROCEDURE  
1. Apply a thin coating of Penetrox A-13  
Electrical Joint Compound to the mating sur-  
faces of the output power board and the heat  
sink. Make sure the surfaces are clean. Do  
not allow the compound to get into the  
threaded holes or on the screw threads.  
CAUTION  
Be sure to follow the recommended static-free  
methods for handling printed circuit boards.  
Failure to do so can result in permanent damage  
to the equipment.  
2. Mount the output power board to the heat  
sink and pre-torque the four socket head  
screws to 25 inch-pounds.  
3. Finish tightening the four screws to 40-48  
inch-pounds.  
4. Replace the four phillips head screws previ-  
ously removed.  
5. Replace leads X20 and X40.  
6. Replace plugs J30, J31, J32, J33, and J34.  
7. Replace leads X4 and X2, then torque to 75  
IN. LBS.  
8. Replace lead B21 and torque it to 75 IN. LBS.  
9. Clear and secure all leads and replace the  
wraparound cover.  
PRO-CUT 80  
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F-50  
F-50  
TROUBLESHOOTING & REPAIR  
PRIMARY POWER BOARD AND FILTER CAPACITOR  
REMOVAL AND REPLACEMENT  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician or  
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manu-  
al.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
DESCRIPTION  
The following procedure will aid the technician in removing the primary power board and fil-  
ter capacitors for maintenance or replacement.  
MATERIALS NEEDED  
5/16” Nut driver  
3/16” Allen type wrench  
7/16” Wrench  
Phillips Head screw driver  
Torque wrench  
3/8” Wrench  
Penetrox A-13 (Lincoln E2529) Electrical Joint Compound  
This procedure takes approximately 40 minutes to perform.  
PRO-CUT 80  
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F-51  
F-51  
TROUBLESHOOTING & REPAIR  
PRIMARY POWER BOARD AND FILTER CAPACITOR  
REMOVAL AND REPLACEMENT (continued)  
FIGURE F.23 – PRIMARY POWER BOARD REMOVAL  
Primary Power  
Board With Input  
Filter Capacitors  
REMOVAL PROCEDURE  
1. Remove input power from the PRO-CUT 80  
machine.  
4. Label the leads for reassembly.  
5. Remove Plug J10 and any necessary cable  
ties.  
2. Remove the case wraparound and perform  
the Input Filter Capacitor Discharge  
Procedure detailed earlier in this section.  
6. Using the 7/16” wrench, remove leads 201,  
202, 203, 204, 205, 206, 207, 208 and 209.  
3. Locate the primary power board and associ-  
ated lead and plug connections. See Figure  
F.23.  
PRO-CUT 80  
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F-52  
F-52  
TROUBLESHOOTING & REPAIR  
PRIMARY POWER BOARD AND FILTER CAPACITOR  
REMOVAL AND REPLACEMENT (continued)  
FIGURE F.24 – POWER BOARD HEATSINK AND CAPACITOR REMOVAL  
Heatsink Mounting  
Screws (4)  
Mounting  
Screws (2)  
Socket Head  
Screws (8)  
7. Using the Phillips Head screw driver, remove  
the two mounting screws from the top right of  
the primary power board. See Figure F.24.  
9. Carefully remove the primary power board  
from the heat sink.  
8. Using the 3/16” allen type wrench, remove  
the eight socket head screws and lock wash-  
ers mounting the primary power board to the  
heat sink.  
CAUTION  
Be sure to follow the recommended static-free  
methods for handling printed circuit boards.  
Failure to do so can result in permanent damage  
to the equipment.  
PRO-CUT 80  
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F-53  
F-53  
TROUBLESHOOTING & REPAIR  
PRIMARY POWER BOARD AND FILTER CAPACITOR  
REMOVAL AND REPLACEMENT (continued)  
CAPACITOR REMOVAL  
1. Using the 3/8” wrench, remove the four  
screws holding the heat sink to the center  
panel assembly. Take note of the insulator  
placement for reassembly. The four screws  
have insulating washers on both sides of the  
panel assembly. These must be properly  
replaced upon reassembly.  
6. Assemble the eight socket head screws and  
pre-torque them to 25 inch-pounds.  
7. Make certain the capacitors are lined up cor-  
rectly so that when the capacitor bolts are  
assembled through the P.C. board, there will  
NOT be any distortion to the P.C. board.  
8. Finish tightening the eight screws to 40-48  
inch-pounds.  
2. Carefully push the heat sink in towards the  
center of the machine. This is necessary to  
gain clearance for capacitor(s) removall.  
9. Assemble the two Phillips Head screws pre-  
viously removed.  
3. Carefully slide the capacitor(s) from the heat  
sink assembly. Observe polarity markings  
and terminal position.  
10. Connect the J10 plug.  
11. Connect leads 201, 204, 205, 208 and 209  
previously removed. Torque to 75 IN. LBS.  
CAPACITOR REPLACEMENT AND  
P.C. BOARD REPLACEMENT  
12. Connect leads 202A, 207A, 206, and 203A  
to the capacitor terminals. Torque to 50-60  
inch-pounds.  
1. Carefully slide the new capacitor(s) into the  
heat sink assembly.  
13. Clear and reposition any leads that may be  
disturbed. Replace wire ties.  
2. Reassemble the heat sink assembly to the  
center panel using the four screws and insu  
lated washers previously removed. Note  
insulation placement.  
14. Replace the case wraparound cover.  
3. Position the capacitors to the P.C.Board for  
assembly. Note the polarity of the  
capacitors.  
4. Apply a thin coating of Penetrox A-13  
Electrical Joint Compound to the mating sur-  
faces of the P.C. board and the heat sink and  
capacitor terminals.  
5. Mount the P.C. board to the heat sink and  
capacitor assembly. Make sure the capacitor  
terminals line up with the holes in the P.C.  
board and with the correct capacitor polari-  
ties.  
PRO-CUT 80  
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F-54  
F-54  
TROUBLESHOOTING & REPAIR  
INPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician or  
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manu-  
al.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
DESCRIPTION  
The following procedure will aid the technician in removing the input rectifier bridge for main-  
tenance or replacement.  
MATERIALS NEEDED  
3/16” Allen type wrench  
Phillips head screw driver  
Torque wrench  
Penetrox A13 (Lincoln E2529) Electrical Joint Compound  
Dow Corning 738 (Lincoln E2861) Electrical Insulating Compound  
This procedure takes approximately 16 minutes to perform.  
PRO-CUT 80  
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F-55  
F-55  
TROUBLESHOOTING & REPAIR  
INPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued)  
5. With the phillips head screw driver, remove  
PROCEDURE  
the lead terminals connected to the rectifier  
1. Remove input power to the PRO-CUT 80.  
terminals.  
2. Perform the Input Filter Capacitor  
6. Using the 3/16” allen wrench, remove the two  
Discharge Procedure detailed earlier in this  
section.  
cap head screws and washers mounting the  
input rectifier bridge to the center panel  
assembly.  
3. Locate the input rectifier and the leads con-  
nected to it. See Figure F.25.  
4. Identify and mark the leads connected to the  
rectifier terminals.  
C
#207A  
#207  
B
A
#209  
TOP VIEW  
FIGURE F.25 – INPUT RECTIFIER LEAD LOCATIONS  
PRO-CUT 80  
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F-56  
F-56  
TROUBLESHOOTING & REPAIR  
INPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued)  
7. Carefully remove the input rectifier bridge.  
8. When installing a new input rectifier apply a  
thin coating of Penetrox A-13 Heat Sink  
Compound (Lincoln E2529) to the mating  
surfaces. Torque the mounting cap screws  
and nuts to 44 in-lbs.  
9. Reconnect the 10 leads to the correct ter-  
minals and torque the phillips head screws  
to 31 in-lbs.  
10. Apply Dow Corning 738 Insulating Com-  
pound to all six screw heads and termi-  
nals. The heavy input lead terminals  
should be against the rectifier terminals.  
11. Assemble case wrap-around cover.  
PRO-CUT 80  
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F-57  
F-57  
TROUBLESHOOTING & REPAIR  
RETEST AFTER REPAIR  
Should a machine under test be rejected for any reason requiring the removal of any mechanical part that could  
affect the machine’s electrical characteristics, or if any electrical components are repaired or replaced, the  
machine must be retested.  
INPUT IDLE AMPS AND WATTS  
Input Volts/Hertz  
Idle Amps  
Idle Watts  
208/230/460  
0.61  
140  
Output Current Range  
35 - 85 Amps  
335 Volts  
Maximum Open Circuit Voltage  
PRO-CUT 80  
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F-58  
F-58  
NOTES  
PRO-CUT 80  
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G-1  
G-1  
ELECTRICAL DIAGRAMS  
TABLE OF CONTENTS  
-ELECTRICAL DIAGRAMS SECTION-  
ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION G  
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-2  
CONTROL PC BOARD SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-3  
CONTROL PC BOARD ASSEMBLY - CODE 10574 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-4  
CONTROL PC BOARD ASSEMBLY - CODE 10577 & 10578 . . . . . . . . . . . . . . . . . . . . . . . . . . G-5  
POWER PC BOARD SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-6  
POWER PC BOARD ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-7  
OUTPUT PC BOARD SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-8  
OUTPUT PC BOARD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-9  
DISPLAY PC BOARD SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-10  
DISPLAY PC BOARD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-11  
PRO-CUT 80  
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G4239  
G4238  
G-2  
G-2  
ELECTRICAL DIAGRAMS  
WIRING DIAGRAM - PRO CUT 80  
RIGHT SIDE OF MACHINE  
INPUT  
PER  
N.A.  
H1  
H2  
H3  
G
R
B
U
W
N
8
53  
-
207A  
12V  
24V  
W
V
H1  
5
2
7
8
3
N
R
56  
51  
F
C
C
207  
2
TP1  
S1  
POWER  
TP3  
E
D1  
54  
C1  
6
R
U
H4  
H5  
H6  
C
B
A
B
B
3000/450  
+
INPUT  
BRIDGE  
+
-
9
5
64  
62  
61  
TP2  
18V  
18V  
W
U
S2  
S3  
PSI_SET  
D
A
A
209  
A
206  
203  
208  
RESET  
4
1
209  
4
277B  
Y
Y
FAN  
FAN  
205  
277A  
J22  
FAN  
FAN  
115V  
223  
501  
502  
503  
1
2
3
4
5
6
221  
RELAY  
++VOLT  
7
505  
506  
J21  
AUXILIARY  
15  
14  
FAN  
+15V  
READY LED  
TRANSFORMER  
216  
P_XFMR  
T2  
507  
POWER  
217  
212  
218  
213  
219  
214  
210  
215  
FAN  
MOTOR  
J10  
13 LOW_PSI LED  
201  
204  
I
12  
11  
10  
POT WIPER  
RESET  
18V  
18V  
T3  
T1  
404  
208  
204  
1
3
2
4
J5  
8
MAIN  
XFMR  
CURRENT  
207A  
I
GND  
TRANSFORMER  
4
3
2
1
203  
Y
Y
507  
506  
505  
THERMAL LED  
RESET LED  
9
8
7
6
5
4
3
2
1
P_XFMR  
S4 PRIMARY RECONNECT  
503  
502  
501  
7
6
5
B
J1  
FR-OUT  
S
202  
207  
++VOLT  
RELAY  
203  
FR-IN  
S
PSI SET  
6
202  
207A  
-
+
6
1
2
3
4
5
C2  
216  
217  
218  
219  
X2  
3000/450  
212  
213  
214  
215  
J4  
7
8
9
275  
276  
2
Y
206  
CT  
3
2
1
6
5
4
Y
3
X20  
7
X4  
223  
277  
221  
205  
201  
404  
401  
202  
S
10  
ELECJ33  
R
W
R
TSTAT  
X3  
W
X30  
210  
1
2
3
4
X1  
XFER  
J2  
S
XFER  
J3  
16  
J40  
X10  
275  
276  
W
R1  
8
W
R
306  
10K  
7,8 ELEC SHUNT (TWIST PR)  
X40  
X20  
N
365  
N
15  
14  
13  
12  
11  
7
6
5
4
2W  
X2  
BK-IN  
360  
277  
A
CONTROL  
B21  
277A  
BK-OUT  
X40  
4,5 XFER SHUNT (TWIST PR)  
POT  
DISPLAY  
W
R
206  
4
2
360  
E
361  
6
1
J31  
CW (MAX)  
12 GND  
366  
369  
364  
X4  
1,2 TRIGGER  
2
3
4
5
11 TRIGGER  
7
8
312  
354  
310  
3
2
1
303  
302  
4
ELECTRODE  
3
IGBT  
3
NOZZLE  
2,6 PSI SWITCH  
10 ELEC SOL  
10  
9
9
10  
5,6 AIR SOL  
7,8 ELEC SOL  
10 WORK  
9
AIR SOL  
309  
SHOWN FOR 400-460VAC OPERATION  
365  
1
2
3
4
4A  
5
6
7
8
2A  
CONTROL  
J34  
A
B
C
D
E
F
G
H
I
J
K
L
M
N
343  
344  
347  
348  
INTERFACE RECEPTACLE  
N.C.  
J32  
1
2
3
4
5
6
7
8
8
2
3
AIR SOL  
ELEC SOL  
TRIGGER  
309  
J20  
Y
A
A
310  
354  
9
10  
1
306  
W
0.6A  
SLOW BLOW  
13 IGBT  
14 GND  
S5  
11  
12  
13  
14  
2
PRESSURE  
H3  
H2  
4
303  
312  
R
302  
361  
366  
WORK  
200-  
208V  
220-  
AIR  
W
230V  
SOLENOID  
J30  
4
5
6
1
2
3
51  
440-  
460V  
380-  
415V  
54  
53  
1,4 24V  
N
N
7
4
2
56  
H5  
H4  
OUTPUT  
12V  
8
369  
364  
L1  
CHOKE  
9
6
E
x x x x x x x  
S
5
401  
E
NOTES:  
N.A.  
1
4
1. FOR MACHINES SUPPLIED WITH INPUT CABLE  
3
2
LEFT SIDE OF MACHINE  
FOR SINGLE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE.  
CONNECT BLACK & WHITE LEADS TO SUPPLY CIRCUIT.  
COLOR CODE:  
WRAP RED LEAD WITH TAPE TO PROVIDE 600V. INSULATION.  
B = BLACK  
G = GREEN  
R = RED  
FOR THREE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE.  
J40  
CONNECT BLACK, RED & WHITE LEADS TO SUPPLY CIRCUIT.  
1
15  
W = WHITE  
U = BLUE  
2. FOR MACHINES NOT SUPPLIED WITH INPUT CABLE  
OUTPUT  
PC BOARD  
BASE  
CASE FRONT  
FOR SINGLE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES.  
CONNECT TERMINALS U & W TO SUPPLY CIRCUIT.  
N = BROWN  
Y = YELLOW  
FOR THREE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES.  
CONNECT TERMINALS U, V & W TO SUPPLY CIRCUIT.  
J4,J10,  
J30  
J1,J20  
J33  
J5,J22,  
J2,J21,J31  
J3  
J32  
J34  
PROTECTIVE BONDING CIRCUIT  
1
1
8
5
2
4
8
7
1
3
1
1
1
8
N.B. SINCE COMPONENTS OR CIRCUITRY OF A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING  
THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT  
COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER.  
9
16  
10  
3
4
5
14  
6
4
6
N.C. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE.  
CONNECTION SHOWN IS FOR 440-460V OPERATION.  
N.D. C1 AND C2 CAPACITORS ARE A MATCHED SET.  
CONNECTOR CAVITY NUMBERING SEQUENCE  
(VIEWED FROM COMPONENT SIDE OF BOARD)  
ELECTRICAL SYMBOLS PER E1537  
XL-RW  
L10936  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.  
PRO-CUT 80  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-3  
G-3  
ELECTRICAL DIAGRAMS  
SCHEMATIC - CONTROL PC BOARD  
Vct  
=
0.01 Ip  
+15V  
+15V  
J4  
3
+15V  
CUTTING CURRENT  
SETPOINT  
...  
LOCAL  
D15  
D16  
C32  
0.1  
X10  
TCF6000  
C56  
D10  
3A  
5
4
3
2
C42  
0.1  
J2  
J2  
C50  
4.7  
1N4936  
1N4936  
Vin  
+
Vc  
OUT  
GND  
INV IN  
.15  
C57  
50V  
6
8
100V  
40V  
1.0  
C55  
J4  
C54  
1.0  
X13  
50V  
35V  
MAX  
MIN  
GATE DRIVE  
PULSE XFMR  
6
100K  
R47  
3
35V  
4.75K  
D
I
S
P
L
A
Y
CONTROL_POT  
COM  
35V  
CUTTING  
CONTROL  
POT  
R45  
3
PRIMARY  
CURRENT  
COM  
D17  
D18  
J5  
J5  
XFORMER  
COM  
C23  
D311A  
40V  
C21  
1.0  
1N4936  
1N4936  
1
125:1  
267  
N.I. IN  
COM  
35V  
26.7  
26.7  
15  
11  
14  
10  
13  
12  
J2  
J2  
+5.5V  
VIN  
AOUT  
BOUT  
SYNC  
Vc  
R140  
9
R121  
D12  
3A  
R122  
4
COM  
CS+  
COMP  
EA-  
R141  
COM  
40V  
7
10.0K  
R154  
267  
1
X12  
C59  
100p  
100V  
+15V  
N.I. IN  
C27  
330p  
100V  
COM  
6
8
X10  
4
5
2
X14  
Vin  
OUT  
Vc  
7
TCF6000  
12  
13  
CT  
GND  
VREF  
CL SS  
CS-  
TCF6000  
X10  
+
DZ1  
12V  
1W  
R152  
R155  
221K  
5
2
1
100  
2
14  
C60  
.018  
/PURGE  
COM  
X2  
33074A  
V_PWM  
EA+  
D13  
3A  
C33  
SHORT  
OPEN  
=
TRIGGER ON  
INV IN  
GND  
20.0K  
R52  
5
+5.5V  
16  
9
DZ2  
12V  
1W  
0.1  
=
TRIGGER OFF  
SHUTDOWN  
RT  
40V  
3
C58  
50V  
PURGE  
COM  
4
50V  
C26  
1.0  
35V  
3.74K  
J3  
C61  
1.8  
20V  
D25  
3
10.0K  
R156  
0.1  
PUSHBUTTON  
B
O
A
R
D
3
C12  
.018  
50V  
TRIGGER CIRCUIT  
OPTOCOUPLER  
X3  
LM224  
50V  
UC2856N  
+5.5V  
1
COM  
R153  
100K  
11  
2
COM  
1.50K  
COM  
3
2
C39  
TRIGGER ON  
=
H
TCF6000  
X10  
+5.5V  
TRIGGER OFF  
=
L
C62  
1.0  
35V  
8.000MHz  
R112  
4.75K  
R137  
1
Y1  
3.32K  
Q5  
100  
5
J2  
/SAFETY_RESET  
Vdd  
+15V  
2N4403  
C46  
10p  
NOTE:  
Shutdown Condition:  
R54  
3
COM  
COM  
825  
X11  
RES  
COM  
CW  
RESET  
C52  
10p  
90 Amps  
=
0.25V  
0.35V  
R102  
C48  
330p  
100V  
PUSHBUTTON  
C28  
1.0  
10K  
100V  
S-8054HN  
126 Amps  
=
5.62K  
+5.5V  
Vss  
100V  
35V  
3.74K  
Q1  
COM  
R99  
2N4401  
10.0K  
R165  
COM  
COM  
10.0K  
+15V  
+5.5V  
COM  
332  
R166  
9
R11  
1
COM  
J3  
52  
6
TCF6000  
X10  
Vss  
VRH  
R/W  
VRL  
D19  
R167  
221K  
R12  
C14  
2
MODB  
/IRQ  
332  
COM  
COM  
19  
51  
5
R13  
R14  
OPTOCOUPLER  
6
332  
4.75K  
12  
13  
18  
/XIRQ  
XTAL  
EXTAL  
PC1  
E
+15V  
X3  
LM224  
AIR SOLENOID  
R17  
THERMOSTAT(S)  
COM  
332  
14  
8
17  
30  
29  
28  
35  
27  
42  
41  
39  
38  
44  
33  
34  
20  
21  
825  
R29  
J4  
J4  
/RESET  
PA4  
PA5  
PA6  
1
R164  
10.0K  
10.0K  
/OUTPUT  
7
X5  
-15V  
-15V  
-15V  
TRIGGER  
SHORT  
OPEN  
=
TEMP OK  
=
H
AIR_SOLENOID  
PILOT_SWITCH  
ELECTRODE_SOLENOID  
PRIMARY_POWER  
READY  
AIR_SOLENOID  
PILOT_SWITCH  
R178  
10  
3.74K  
R58  
=
OVERTEMP  
=
L
C13  
+5.5V  
Q2  
16  
14  
47  
12  
PC7  
10.0K  
4
COM  
2N4401  
THERMOSTAT OK  
CONTROL_POT  
/PURGE  
ELECTRODE_SOLENOID  
PC5  
PB7  
PA7  
PB0  
PB1  
COM  
COM  
PE2  
TCF6000  
X10  
3
PSI  
PC3  
J3  
/SAFETY_RESET  
SAFETY  
D22  
9
PC0  
100  
R56  
7
J3  
J3  
/PSI_OK  
/PSI_OK  
PRIMARY VOLTAGE  
SENSE_AMPS  
AIR_LOW  
13  
PC4  
PB3  
PB4  
PE4  
COM  
6
OPTOCOUPLER  
THERMAL  
43  
49  
15  
PRESSURE SWITCH  
C30  
PE0  
4.75K  
1.0  
+15V  
2
PE3  
IGBT DRIVE  
35V  
825  
R91  
/PIP  
PC6  
PA1  
COM  
ELECTRODE_AMPS  
/RETRACT_ARC  
45  
32  
36  
40  
PE1  
PA0  
PD0  
PD1  
+5.5V  
3.74K  
R100  
PA2  
TCF6000  
X16  
Q3  
+5.5V  
PB6  
2N4401  
10  
9
10.0K  
R104  
3
PB2  
MODA  
11  
1
14  
3
R158  
10.0K  
R160  
TACH INPUT  
TACH INPUT  
NC  
NC  
TCF6000  
X16  
8
X2  
33074A  
10.0K  
4
22  
11  
AS  
PD2 (MISO)  
PC2  
10.0K  
13  
12  
10  
C38  
R23  
X15  
37  
23  
24  
PB5  
1.30K  
J5  
J3  
3
4
6
7
2
GND  
/CLR  
4
GND  
/
X17  
D24  
7
5
COM  
46  
48  
50  
31  
PD3 (MOSI)  
PD4 (SCK)  
PD5 (CS_D/A)  
Vdd  
PE5  
PE6  
PE7  
PA3  
5
VREF  
PRIMARY CAP  
OPTOCOUPLER  
ISOURCE  
IBIAS  
NC  
NC  
Ic  
SDI  
CLK  
/LD  
8
3
2
1
COM  
CW  
COM  
10  
9
VDD  
OPTOCOUPLER  
IBIAS  
V+  
COM  
7
4.75K  
6
2
25  
26  
R159  
VOUT  
COM  
SENSE_AUX  
50K  
6
+5.5V  
ELECTRODE SOLENOID  
MS-001BA  
1.21K  
C67  
1.0  
35V  
10.0K  
8
ISINK  
68HC711E9  
100K  
R183  
C40  
LM2907  
R188  
+15V  
39.2K  
C70  
.0047  
50V  
J5  
C29  
COM  
DZ3  
5.1V  
1W  
1.0  
50V  
RELAY  
COILS  
1
10.0  
10.0  
J5  
R110  
R111  
COM  
C6  
COM  
COM  
.0047  
D20  
R196  
10.0  
R197  
10.0  
C11  
1400V  
+15V  
R189  
5
COM  
PRE-CHARGE  
J5  
D
S
+15V  
DISABLE  
Q4  
CW  
6.81K  
R109  
G
4A  
PRIMARY_POWER  
1K  
100V  
3
COM  
X2  
33074A  
9
1
150p  
50V  
C43  
LM224  
X3  
8
2
R60  
COM  
10  
15.0K  
R15  
R64  
OUTPUT  
BOARD  
1
8
1.00K  
NULL  
INPUT  
INPUT  
NULL  
V_PWM  
7
D
1.00K  
R70  
47.5K  
X16  
TCF6000  
R25  
R115  
READY  
243  
R39  
243  
R34  
J3  
J3  
7
I
J2  
J2  
J2  
J2  
3
2
V
CC  
COM  
100K  
3.32K  
S
P
L
A
Y
5
511  
R42  
511  
R96  
2.43K  
R98  
X6  
6
5
2
3
10  
9
OUT  
NC  
7.68K  
6
X1  
C47  
4
LT1014  
1
8
X1  
LT1014  
V
EE  
10  
2
R73  
R116  
PIP  
D21  
1.0A  
30V  
C53  
OP27  
D14  
R48  
C15  
0.1  
50V  
C18  
.47  
50V  
3.32K  
28.0K  
R72  
1.50K  
COM  
C44  
150p  
AIR_LOW  
10.0K  
R93  
R117  
243  
R38  
COM  
C35  
B
O
A
R
D
COM  
3.32K  
R37  
243  
4
50V  
COM  
+15V  
C45  
COM  
4
THERMAL  
R118  
R89  
3.32K  
100K  
2700p  
50V  
COM  
R79  
221K  
1.30K  
221K  
R83  
TCF6000  
X16  
SENSE_AUX  
+15V  
+5.5V  
+15V  
R192  
J3  
POWER SUPPLY  
C22  
12  
MACHINE OVERVIEW  
D5  
D6  
150p  
50V  
5
COM  
COM  
+15V  
+5.5V  
-15V  
1.21K  
R78  
5
6
CW  
13  
12  
X3  
LM224  
TRANSFER  
SHUNT  
100K  
R80  
R84  
1K  
1V  
=
68.07mA  
7
14  
X1  
7805  
X8  
S18395-13 ASSY  
10.0K  
1.0  
5W  
LT1014  
LM350  
X7  
CUT  
DIODES  
R1  
C4  
IN  
OUT  
C72  
0.1  
COM  
R81  
IN  
OUT  
.47  
S18647 ASSY  
ADJ  
D2  
1.30K  
475  
1.30K  
LED3  
D23  
10.0K  
CUT  
50V  
50V  
WINDINGS  
D1  
D9  
GND  
COM  
AUX XFMR  
J1  
6.19K  
1
COM  
1
8
C1  
NULL  
INPUT  
INPUT  
NULL  
TCF6000  
X16  
243  
R36  
R40  
3300  
J3  
TP1  
50V  
15J  
7
3
2
LED1  
LED2  
C71  
0.1  
C3  
1000  
35V  
V
CC  
WORK  
R33  
243  
50V  
C5  
100  
50V  
CW  
8
GAIN  
1V  
=
80.0  
X4  
18VAC  
CT  
NOTE:  
SOME OR ALL OF THESE  
6
5
OUT  
NC  
10K  
221  
R35  
221  
=
12.50  
A
R28  
3.32K  
50V  
RESISTORS MAY NOT BE PRESENT  
6
5
4
C36  
4
X1  
V
EE  
J1  
J1  
R24  
LT1014  
2
7
OP27  
C16  
C31  
NOZZLE  
C7  
50  
50V  
C9  
27  
D8  
0.1  
C17  
TP2  
50V  
15J  
POWER SUPPLY  
CALIBRATION  
18VAC  
COM  
COM  
50V  
GND  
35V  
PILOT  
WINDINGS  
10.0K  
ELECTRODE  
SHUNT  
-15V  
L1  
IN  
OUT  
J3  
COM  
C37  
X9  
7915  
COM  
COM  
7
R32  
243  
R30  
243  
R26  
4
PILOT  
DIODES  
D3  
COM  
D7  
D4  
COM  
+15V  
4
+15V  
+5.5V  
+5.5V  
FILENAME: G3353_1CA  
7
7
4
4
13  
8
8
26  
9
7
C68  
C69  
C63  
C64  
C66  
Vdd  
GENERAL INFORMATION  
LAST NO. USED  
C25  
4.7  
35V  
C20  
C41  
R- 197  
C- 72  
D- 25  
X- 17  
Y-  
TP-  
LED-  
1
C10  
C24  
C51  
C49  
ELECTRICAL SYMBOLS PER E1537  
C19  
X5  
X2  
Q-  
5
2
X1  
X3  
X17  
X15  
X6  
X4  
X16  
X10  
X12  
CAPACITORS  
RESISTORS  
DIODES  
=
MFD  
(
.022/50V  
1/4W  
UNLESS OTHERWISE SPECIFIED)  
UNLESS OTHERWISE SPECIFIED)  
C34  
DZ-  
3
3
4.7  
35V  
LABELS  
=
Ohms  
(
OP27  
COM  
C8  
OP27  
4
LT1014  
COM  
LM224  
11  
TCF6000  
1
TCF6000  
1
68HC711E9  
LM2907  
12  
MS-001BA  
5
33074A  
11  
UC2856N  
12  
=
1A, 400V  
(UNLESS OTHERWISE SPECIFIED)  
SUPPLY  
VOLTAGE NET  
Vss  
4
11  
1
C2  
14  
C65  
POWER SUPPLY SOURCE POINT  
COMMON CONNECTION  
COM  
COM  
REF. DESIGNATORS SKIPPED:  
-15V  
R51,R59,R66,R71,R74,R75,R86,R90,R92,R95,R105,R119,  
R143-R146,R150,R151,R161-R163,R168,R169,R185,R186  
FRAME CONNECTION  
X16  
16  
15  
13  
EARTH GROUND CONNECTION  
1
2
5
J3 J3 J3 J3 J3  
POWER  
SUPPLY  
TO: DISPLAY  
BOARD  
TO: OUTPUT  
BOARD  
J3  
TO: CT  
&
TO: POWER  
7
X2  
33074A  
TSTATS  
J4  
BOARD  
J5  
NOTES  
:
6
J1  
1
J2  
2
4
1
5
1
8
1
3
6
1
4
8
N.A. SINCE COMPONENTS OR CIRCUITRY ON  
A
PRINTED CIRCUIT BOARD MAY CHANGE  
3-19-99  
3
1
2
5
4
8
WITHOUT AFFECTING THE INTERCHANGEABILITY OF COMPLETE BOARD, THIS DIAGRAM MAY  
A
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING  
NUMBER.  
A
COMMON CODE  
G
3353  
J1 J2 J4 J4 J5 J5  
3
6
10  
9
16  
4
5
COM  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
PRO-CUT 80  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-4  
G-4  
ELECTRICAL DIAGRAMS  
PC BOARD ASSEMBLY - CONTROL BOARD (CODE 10574 ONLY)  
ITEM  
PART NO.  
DESCRIPTION  
REQ'D  
C1  
)
1
30  
)
S13490-92  
S16668-5  
)
3300/50  
.022/50  
C2,C8,C10,C11,C13,C14,C17  
C20,C23,C24,C31,C34,C35  
C36,C37,C38,C39,C40,C41  
C47,C49,C51,C53,C55,C63  
C64,C65,C66,C68,C69  
)
)
)
C3  
C4,C18  
C5  
C6  
C7  
C9  
C12,C60  
C15,C16,C32,C33,C42,C58  
)
1
2
1
1
1
1
2
8
)
)
S13490-121  
S13490-63  
S13490-71  
T11577-52  
S13490-72  
S13490-93  
S13490-126  
S16668-11  
)
)
)
1000/35  
.47/50  
100/50  
.0047 or .005/1400  
50/50  
27/35  
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
.018/50V  
.1/50  
)
)
)
C71,C72  
C19,C25,C50  
C21,C26,C28,C30,C54,C57  
C62,C67  
)
3
8
)
)
S13490-25  
S13490-42  
)
4.7/35  
1.0/35  
)
C22,C43,C44  
C27,C48  
C29  
C45  
C46,C52  
C56  
C59  
C61  
C70  
)
3
2
1
1
2
1
1
1
)
)
)
)
)
)
)
)
)
S16668-9  
S16668-8  
S13490-135  
S16668-4  
S16668-13  
S13490-108  
S16668-3  
S13490-19  
S16668-10  
T12199-1  
)
)
150pF/100  
330pF/100  
1.0/50V  
2700pF/50  
10pF/100  
.15/100  
100pF/100  
1.8/20  
4700pF/50  
1N4004  
)
)
)
)
)
)
)
)
)
)
)
)
)
)
1
16  
)
)
D1,D2,D3,D4,D5,D6,D7,D8,D9  
D14,D19,D20,D22,D23,D24  
D25  
)
)
~.04  
6.00  
D10,D11,D12,D13  
D15,D16,D17,D18  
D21  
DZ1,DZ2  
DZ3  
J1  
J2  
J3  
)
4
4
1
2
1
1
1
1
1
1
3
3
1
1
1
3
9
)
T12705-37  
T12705-34  
T12705-23  
T12702-19  
T12702-52  
S18248-4  
S18248-10  
S18248-16  
S18248-6  
)
1N5822 SCHOTTKY BARRIER DIODE  
1N4936  
1N5818  
1N4742A  
1N4733A  
HEADER  
HEADER  
HEADER  
HEADER  
HEADER  
RED LED  
2N4401  
HEXFET TRANS. (SS)  
2N4403  
1.0 OHM, 5W RESISTOR  
2.67K 1/4W  
243 1/4W  
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
5.75  
PRO-CUT 80 CONTROL  
)
)
G3443-1  
C70  
C52  
)
C67  
X11  
C49  
)
)
)
)
)
)
LED2  
Y1  
)
)
)
)
)
R173  
X8  
X17  
X15  
J4  
J5  
C46  
S18248-8  
T13657-2  
R132  
R136  
LED1,LED2,LED3  
Q1,Q2,Q3  
Q4  
Q5  
)
)
T12704-68  
T12704-80  
T12704-69  
T13165-16  
S19400-2671  
S19400-2430  
)
R61  
X10  
X5  
)
)
)
)
)
R133  
R3  
R2  
R62  
R63  
R187  
X7  
R1  
)
C3  
C20  
C55  
R2,R46,R187  
R3,R30,R32,R33,R34,R36,R37  
R38,R39  
)
)
)
Q5  
)
C54  
R4  
R5  
R6  
)
)
)
1
1
1
5
1
7
)
)
)
)
)
)
S19400-30R1  
S19400-6190  
S19400-8251  
S19400-3921  
S19400-2001  
S19400-1001  
)
30.1 1/4W  
619 1/4W  
8.25K 1/4W  
3.92K 1/4W  
2.0K 1/4W  
1K 1/4W  
X16  
)
)
X12  
LED1  
LED3  
)
D5  
R7,R190,R191,R193,R194  
R8  
R9,R15,R50,R64,R88,R103  
R113  
R10,R42,R96  
R11,R12,R13,R14  
R16,R21  
R17,R23,R26,R27,R61,R62  
R63,R68,R69,R81,R84,R93  
R94,R104,R106,R108,R134  
R138,R139,R154,R156,R158  
R160,R164,R165,R166,R178  
R179,R180,R181,R182  
)
3.75  
C44  
C45  
C31  
)
)
)
R98  
D21  
)
R48  
)
3
4
2
)
S19400-5110  
S19400-3320  
S19400-3322  
S19400-1002  
)
)
)
)
511 1/4W  
332 1/4W  
33.2K 1/4W  
10K 1/4W  
R88  
R24  
)
)
)
R188  
C29  
X1  
)
C17  
R35  
R189  
)
31  
)
X2  
DZ2  
C33  
R140  
R73  
C18  
R18  
R50  
R64  
R60  
X9  
R41  
C11  
D14  
R18  
)
1
7
)
)
S24073-1  
S19400-5111  
)
10K,1/2W,TRIMMER  
5.11K 1/4W  
C1  
R19,R53,R55,R57,R85,R149  
R157  
)
)
R20,R22,R110,R111,R124  
R125,R126,R127,R128,R142  
R196,R197  
)
12  
)
S19400-10R0  
)
10 1/4W  
X6  
X4  
C50  
R19  
DZ1  
R24,R35  
)
2
7
)
)
S19400-2210  
S19400-1003  
)
)
)
221 1/4W  
100K 1/4W  
R17  
C42  
R25,R47,R49,R80,R89,R153  
R183  
R28,R112,R115,R116,R117  
R118,R133  
)
)
)
Q4  
X3  
)
7
)
S19400-3321  
3.32K 1/4W  
R29,R91,R102  
)
3
1
1
4
9
)
)
)
)
)
S19400-8250  
S19400-1004  
S19400-6191  
S19400-1502  
S19400-4751  
)
)
825 1/4W  
1M 1/4W  
6.19K 1/4W  
15K 1/4W  
4.75K  
R31  
R40  
)
)
R111  
D20  
C6  
R41,R60,R135,R184  
R43,R44,R45,R130,R136,R137  
R170,R171,R172  
)
)
)
R110  
C32  
)
R197  
J5  
R196  
R48  
)
1
3
4
2
4
2
2
4
2
4
1
1
1
1
4
1
1
2
1
1
1
1
1
2
2
1
1
1
)
)
)
)
)
S19400-2802  
S19400-1000  
S19400-3741  
S19400-2211  
S19400-4752  
S19400-1501  
S19400-7681  
S19400-1301  
S19400-1211  
S19400-2213  
S19400-8252  
S19400-2431  
S19400-6811  
S19400-5621  
S19400-26R7  
S19400-1212  
S16296-5  
S19400-2670  
S19400-2002  
T10812-39  
S19400-6812  
S19400-4750  
S19400-3922  
T10812-68  
)
)
)
28.0K 1/4W  
100 1/4W  
3.74K 1/4W  
2.21K 1/4W  
47.5K 1/4W  
1.5K 1/4W  
7.68K 1/4W  
1.3K 1/4W  
1.21K 1/4W  
221K 1/4W  
82.5K 1/4W  
2.43K 1/4W  
6.81K 1/4W  
5.62K 1/4W  
26.7 1/4W  
12.1K 1/4W  
10K TRIMMER  
267 1/4W  
20K 1/4W  
50K 1/2W TRIMMER  
68.1K 1/4W  
475 1/4W  
39.2K 1/4W  
1K 1/2W TRIMMER  
15J  
IC,LT1014,LINEAR INTEGRATED CIRCUIT  
IC,33074A,OP-AMP,QUAD,HIGH-PERF  
IC,LM224,OP-AMP  
R52,R54,R56  
R58,R76,R99,R100  
R65,R129  
R67,R70,R87,R101  
R72,R195  
R73,R107  
R77,R82,R175,R177  
R78,R159  
R79,R83,R155,R167  
R97  
)
)
)
J1  
J3  
J4  
J2  
)
)
)
)
)
)
)
)
)
)
)
)
)
)
.25  
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
0
)
)
R98  
R109  
R114  
)
)
)
)
)
)
R120,R121,R122,R123  
R131  
R132  
)
~.04  
0
)
)
9.00  
8.75  
)
R140,R141  
R152  
R173  
R174  
R176  
R188  
R189,R192  
TP1,TP2  
)
)
)
)
)
)
)
)
)
)
.85  
3.55  
8.15  
.25  
)
)
)
CAPACITORS  
INDUCTANCE  
RESISTANCE  
=
=
=
MFD/VOLTS  
HENRIES  
OHMS  
)
)
)
)
T13640-15  
S15128-16  
S15128-18  
S15128-4  
X1  
X2  
X3  
)
)
)
)
)
3-19-99  
3443-1B3  
G
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 pro-  
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the  
machine.  
PRO-CUT 80  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-5  
G-5  
ELECTRICAL DIAGRAMS  
PC BOARD ASSEMBLY - CONTROL BOARD (CODE 10577 & 10578 ONLY)  
!%ÏG  
3
3
ITEM  
1
PART NO.  
DESCRIPTION  
REQ'D  
3300/50  
S16668-5 .022/50  
!%ÏG  
G3560-1B3  
C1  
S13490-92  
C2,C8,C10,C11,C13,C14,C17  
C20,C23,C24,C31,C34,C35  
C36,C37,C38,C39,C40,C41  
C47,C49,C51,C53,C55,C63  
C64,C65,C66,C68,C69  
30  
N.C.  
C3  
C4,C18  
C5  
C6  
C7  
1
S13490-121  
S13490-63  
S13490-71  
T11577-52  
S13490-72  
S13490-93  
S13490-126  
1000/35  
.47/50  
100/50  
.0047 or .005/1400  
50/50  
27/35  
2
1
1
1
1
N.G.  
1
2
C9  
C12,C60  
N.A.  
2
.018/50V  
N.F.  
C15,C16,C32,C33,C42,C58  
C71,C72  
8
S16668-11  
.1/50  
C19,C25,C50  
3
S13490-25  
4.7/35  
C21,C26,C28,C30,C54,C57  
C62,C67  
8
S13490-42 1.0/35  
~.04  
C22,C43,C44  
C27,C48  
C29  
C45  
C46,C52  
C56  
C59  
C61  
C70  
3
S16668-9  
S16668-8  
150pF/100  
330pF/100  
1.0/50V  
2700pF/50  
10pF/100  
.15/100  
100pF/100  
1.8/20  
2
2
6.00  
1
1
S13490-135  
S16668-4  
S16668-13  
S13490-108  
S16668-3  
5.75  
PRO-CUT 80 CONTROL  
G3560-1  
1
1
1
1
C70  
C52  
C67  
X11  
S13490-19  
S16668-10  
C49  
4700pF/50  
LED2  
Y1  
D1,D2,D3,D4,D5,D6,D7,D8,D9  
D14,D19,D20,D22,D23,D24  
D25  
16  
T12199-1  
1N4004  
R173  
X8  
X17  
X15  
C46  
D10,D11,D12,D13  
D15,D16,D17,D18  
D21  
DZ1,DZ2  
DZ3  
J1  
J2  
J3  
4
4
T12705-37  
T12705-34  
1N5822 SCHOTTKY BARRIER DIODE  
1N4936  
R132  
R136  
R61  
1
1
T12705-23  
T12702-19  
T12702-52  
S18248-4  
S18248-10  
S18248-16  
S18248-6  
S18248-8  
1N5818  
1N4742A  
X10  
X5  
R133  
R187  
2
R3  
R2  
R62  
R63  
1N4733A  
HEADER  
HEADER  
HEADER  
HEADER  
HEADER  
X7  
C3  
1
C20  
C55  
1
1
1
1
Q5  
C54  
J4  
J5  
X16  
X12  
LED1,LED2,LED3  
3
T13657-2  
RED LED  
LED1  
LED3  
D5  
Q1,Q2,Q3  
Q4  
Q5  
R1  
R2,R46,R187  
R3,R30,R32,R33,R34,R36,R37  
R38,R39  
R4  
R5  
R6  
R7,R190,R191,R193,R194  
R8  
R9,R15,R50,R64,R88,R103  
R113  
R10,R42,R96  
R11,R12,R13,R14  
R16,R21  
R17,R23,R26,R27,R61,R62  
R63,R68,R69,R81,R84,R93  
R94,R104,R106,R108,R134  
R138,R139,R154,R156,R158  
R160,R164,R165,R166,R178  
R179,R180,R181,R182  
3
T12704-68  
2N4401  
HEXFET TRANS. (SS)  
2N4403  
3.75  
1
1
1
T12704-80  
T12704-69  
T13165-16  
3
C44  
C45  
C31  
N.F.  
R98  
D21  
1.0 OHM, 5W RESISTOR  
R48  
S19400-2671  
2.67K 1/4W  
R88  
9
S19400-2430 243 1/4W  
R24  
R188  
C29  
X1  
C17  
R35  
1
1
1
S19400-30R1  
S19400-6190  
S19400-8251  
30.1 1/4W  
619 1/4W  
8.25K 1/4W  
R189  
X2  
DZ2  
C33  
R140  
5
S19400-3921  
3.92K 1/4W  
R73  
C18  
R18  
1
S19400-2001  
2.0K 1/4W  
R50  
R64  
R60  
7
S19400-1001  
1K 1/4W  
X9  
R41  
C11  
D14  
C1  
3
S19400-5110  
S19400-3320  
511 1/4W  
332 1/4W  
33.2K 1/4W  
4
2
S19400-3322  
31  
X6  
X4  
S19400-1002  
10K 1/4W  
C50  
R19  
N.F.  
DZ1  
R17  
C42  
3
Q4  
X3  
R18  
1
S24073-1  
10K,1/2W,TRIMMER  
S19400-5111 5.11K 1/4W  
R19,R53,R55,R57,R85,R149  
R157  
7
R20,R22,R110,R111,R124  
R125,R126,R127,R128,R142  
R196,R197  
12  
S19400-10R0  
10 1/4W  
R111  
D20  
C6  
R110  
C32  
R24,R35  
2
S19400-2210  
7
221 1/4W  
S19400-1003  
R197  
J5  
R196  
R25,R47,R49,R80,R89,R153  
R183  
R28,R112,R115,R116,R117  
R118,R133  
100K 1/4W  
3.32K 1/4W  
7
S19400-3321  
J1  
J3  
J4  
J2  
R29,R91,R102  
R31  
R40  
R41,R60,R135,R184  
R43,R44,R45,R130,R136,R137  
R170,R171,R172  
3
S19400-8250  
825 1/4W  
1M 1/4W  
6.19K 1/4W  
15K 1/4W  
S19400-4751 4.75K  
1
1
S19400-1004  
S19400-6191  
.25  
4
S19400-1502  
9
0
R48  
1
S19400-2802  
S19400-1000  
S19400-3741  
S19400-2211 2.21K 1/4W  
S19400-4752 47.5K 1/4W  
28.0K 1/4W  
100 1/4W  
3.74K 1/4W  
R52,R54,R56  
R58,R76,R99,R100  
R65,R129  
R67,R70,R87,R101  
R72,R195  
R73,R107  
R77,R82,R175,R177  
R78,R159  
R79,R83,R155,R167  
R97  
3
4
2
4
N.E.  
2
2
S19400-1501  
S19400-7681  
1.5K 1/4W  
7.68K 1/4W  
~.04  
0
9.00  
4
S19400-1301  
1.3K 1/4W  
1.21K 1/4W  
S19400-2213 221K 1/4W  
2
S19400-1211  
4
.85  
1
1
1
S19400-8252  
S19400-2431  
S19400-6811  
S19400-5621  
82.5K 1/4W  
2.43K 1/4W  
6.81K 1/4W  
5.62K 1/4W  
3.55  
8.15  
8.75  
.25  
R98  
R109  
R114  
1
R120,R121,R122,R123  
R131  
R132  
4
S19400-26R7  
26.7 1/4W  
1
1
S19400-1212  
S16296-5  
12.1K 1/4W  
10K TRIMMER  
R140,R141  
R152  
R173  
R174  
R176  
R188  
R189,R192  
TP1,TP2  
2
S19400-2670  
S19400-2002  
T10812-39  
S19400-6812  
S19400-4750  
S19400-3922  
T10812-68  
T13640-15  
267 1/4W  
20K 1/4W  
50K 1/2W TRIMMER  
68.1K 1/4W  
475 1/4W  
39.2K 1/4W  
1K 1/2W TRIMMER  
15J  
1
1
1
1
1
2
2
CAPACITORS  
INDUCTANCE  
RESISTANCE  
=
=
=
MFD/VOLTS  
HENRIES  
OHMS  
X1  
X2  
X3  
1
1
1
S15128-16  
S15128-18  
S15128-4  
IC,LT1014,LINEAR INTEGRATED CIRCUIT  
IC,33074A,OP-AMP,QUAD,HIGH-PERF  
IC,LM224,OP-AMP  
Ch'ge. Sht. No.  
XA  
UNLESS OTHERWISE SPECIFIED TOLERANCE  
ON HOLE SIZES PER E2056  
THIS SHEET CONTAINS PROPRIETARY INFORMATION  
EQUIP.  
INVERTER WELDERS  
THE LINCOLN ELECTRIC CO.  
OWNED BY  
AND IS  
TYPE  
THE LINCOLN ELECTRIC CO.  
ON  
ON  
2
3
PLACE DECIMALS IS .02  
PLACE DECIMALS IS .002  
CLEVELAND, OHIO U.S.A.  
NOT TO BE REPRODUCED, DISCLOSED OR USED  
WITHOUT THE EXPRESS PERMISSION OF  
3-19-99A  
CONTROL P.C. BD AS'BLY (CANADIAN)  
SUBJECT  
ON ALL ANGLES IS .5 OF  
MATERIAL TOLERANCE (" ") TO AGREE  
A
DEGREE  
SCALE  
FULL  
t
SHT.  
THE LINCOLN ELECTRIC CO.  
G3443-1  
DRS  
2-9-99  
REF.  
3560-1B3  
DR  
DATE  
CHK  
SUP'S'D'G  
WITH PUBLISHED STANDARDS.  
NO.  
G
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 pro-  
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the  
machine.  
PRO-CUT 80  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-6  
G-6  
ELECTRICAL DIAGRAMS  
SCHEMATIC - POWER PC BOARD  
209  
POSITIVE  
B209  
INPUT RECTIFIER  
+15V  
+15V  
CR2  
3
4
6
4
6
R23  
R24  
R25  
4
4
150K  
150K  
150K  
CR2  
5
R1  
R2  
C8  
C19  
X1  
X3  
40  
10W  
40  
10W  
40  
10W  
CR1  
3
LM224  
11  
LM224  
11  
CAPACITOR  
150K  
1.00K  
R97  
+15V  
PRECHARGE  
R4  
1.00K  
R33  
CR1  
5
40  
10W  
UNDERVOLTAGE  
PROTECTION  
R27  
100  
J10  
5
1
1
5
1
Q1  
100K  
6
OCI1  
CNY17-3V  
OCI3  
CNY17-3V  
R92  
2
1
4A  
DZ7  
12V  
1W  
D18  
(RELAY DRIVE)  
CR2  
CR1  
2
1
7
900V  
D20  
22.1K  
X1  
5
4
6
2
FROM CONTROL BD.  
4
6
2
Q3  
1A  
100V  
C17  
18  
15V  
J10  
C16  
4
RECONNECT  
206  
1.0  
R85  
1.00M  
44.2K  
C5  
150p  
50V  
35V  
C18  
150p  
50V  
TEST D  
R14  
10.0  
DZ4  
6.2V  
1W  
R19  
10.0  
R20  
C4 C3 C2 C1  
R80  
1K  
R81  
G1  
1K  
5W  
DZ5  
15V  
1W  
G2  
G3  
G4  
A2  
5W  
1.00K  
1.00K  
1.00K  
1.00K  
10.0  
R21  
1K  
5W  
C3  
.0047  
50V  
C22  
C4  
10.0  
E4 E3 E2  
E1  
DZ6  
D2  
1A  
1000V  
.022  
.022  
15V  
1W  
R22  
2000V  
2000V  
BLEEDER  
10.0  
B205  
1K  
PEAK DETECTOR  
RESISTORS  
C1  
A1  
5W  
TRANSFORMER  
PRIMARY  
205  
D15  
A2  
DZ15  
C13  
50  
25V  
+15V  
1K  
206  
12V  
1W  
5W  
150K  
150K  
C1  
A1  
C26  
.22  
C27  
325VDC  
FILTER  
CAPACITOR  
D6  
.22  
1K  
1000V  
1000V  
(NOMINAL)  
5W  
A1  
R83  
1.00M  
+15V  
10  
9
203  
12  
13  
8
X3  
TEST C  
14  
B208  
X1  
R13  
10.0  
DZ2  
2.8K  
10.0  
D3  
D5  
J10  
5
1.00K  
+
1
R9  
TRANSFORMER  
PRIMARY  
208  
C7  
27  
35V  
R40  
X2  
8
10K  
10.0  
R10  
C4 C3 C2 C1  
6.2V  
1W  
C21  
27  
35V  
REF  
24.3K  
G1  
TL431  
-
1
5
6
G2  
G3  
G4  
10.0  
R11  
A1  
OCI4  
CNY17-3V  
DZ3  
15V  
1W  
OVERVOLTAGE  
PROTECTION  
562  
TO CONTROL BD.  
1.00K  
1.00K  
1.00K  
1.00K  
10.0  
R12  
2
6
4
C23  
C1  
.022  
2000V  
+15V  
MISCONNECTION  
PROTECTION  
E4 E3 E2  
E1  
.022  
D1  
1A  
1000V  
(VOLTAGE PROTECTION)  
DZ1  
2000V  
C2  
.0047  
50V  
5
15V  
1W  
G1  
GATE  
S1  
T1  
C15  
150p  
50V  
R84  
8
3
203A  
RECONNECT  
1.00M  
G2  
J10  
2
10  
J10  
J10  
GATE  
1
6
3
X1  
S2  
10  
4
8
D16  
DRIVE  
9
S3  
202A  
RECONNECT  
GATE  
12  
C6  
10.0  
DZ16  
TEST B  
9
G3  
R63  
6
R119  
R118  
221K  
S4  
FROM  
CONTROL  
BOARD  
10.0  
12V  
1W  
GATE  
221K  
7
G4  
R68  
C4 C3 C2 C1  
6.2V  
1W  
C14  
G1  
221K  
Q2  
1A  
100V  
10.0  
1.0  
31.6K  
G2  
G3  
G4  
35V  
R69  
A4  
(PWM DRIVE)  
DZ12  
15V  
1W  
DZ11  
10.0  
1.00K  
1.00K  
1.00K  
1.00K  
R70  
C11  
.0047  
C24  
C12  
E4 E3 E2  
E1  
10.0  
R71  
D9  
1A  
1000V  
.022  
.022  
V/F CONVERTER  
D23  
DZ13  
50V  
2000V  
2000V  
15V  
1W  
R78  
R77  
+15V  
B204  
1K  
5W  
1K  
5W  
R98  
R99  
R100  
16.5K  
R101  
R102  
15.0K  
150K  
332K  
6.19K  
C1  
1K  
TRANSFORMER  
PRIMARY  
204  
+15V  
13  
12  
5W  
5
6
X3  
A4  
14  
6.19K  
7
R82  
X3  
R103  
1.00M  
D21  
6.19K  
3
2
A1  
1K  
1
202  
X1  
R110  
5W  
D4  
C1  
A1  
15.0K  
R107  
150K  
R108  
332K  
R109  
10.0K  
C28  
.22  
1000V  
C29  
FILTER  
CAPACITOR  
325VDC  
.22  
+15V  
+15V  
D7  
1000V  
(NOMINAL)  
150K  
150K  
1K  
A3  
OVERVOLTAGE  
PROTECTION  
D22  
BLEEDER  
RESISTORS  
5W  
207  
R111  
TEST A  
B201  
1.0  
R62  
1K  
1W  
10.0  
Q4  
10.0  
2
3
TRANSFORMER  
C20  
0.27  
50V  
1A  
DZ9  
R58  
5W  
100V  
C4 C3 C2 C1  
1
Q5  
1A  
PRIMARY  
6.2V  
1W  
X3  
G1  
R59  
10.0  
201  
R114  
G2  
G3  
G4  
DZ10  
15V  
100V  
A3  
1.00K  
47.5K  
1.00K  
1.00K  
1.00K  
R60  
10.0  
C10  
.0047  
50V  
1W  
D24  
C25  
C9  
D8  
1A  
1000V  
DZ14  
15V  
1W  
.022  
.022  
E4 E3 E2  
E1  
DZ8  
R61  
10.0  
TEST E  
2000V  
2000V  
15V  
1W  
300 Volts  
=
1kHz (calibrated)  
NEGATIVE  
INPUT RECTIFIER  
207A  
dF  
=
9.5136 dV  
3-19-99A  
G 3518  
FILE NAME: G3518_1CA  
NOTE: 202,203,206,&207 BOLT ON WITH FILTER CAPS  
GENERAL INFORMATION  
LAST NO. USED  
NOTES  
:
R- 119  
C- 29  
D- 24  
Q-  
CR-  
DZ- 16  
5
X-  
3
ELECTRICAL SYMBOLS PER E1537  
N.A. SINCE COMPONENTS OR CIRCUITRY ON  
A
PRINTED CIRCUIT BOARD MAY CHANGE  
2
OCI-  
4
CAPACITORS  
RESISTORS  
DIODES  
=
MFD  
(
.022/50V  
1/4W  
UNLESS OTHERWISE SPECIFIED)  
UNLESS OTHERWISE SPECIFIED)  
WITHOUT AFFECTING THE INTERCHANGEABILITY OF COMPLETE BOARD, THIS DIAGRAM MAY  
A
T-  
1
LABELS  
SUPPLY  
=
Ohms  
(
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING  
NUMBER.  
A
COMMON CODE  
=
1A, 400V  
(UNLESS OTHERWISE SPECIFIED)  
VOLTAGE NET  
POWER SUPPLY SOURCE POINT  
COMMON CONNECTION  
FRAME CONNECTION  
EARTH GROUND CONNECTION  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
PRO-CUT 80  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-7  
G-7  
ELECTRICAL DIAGRAMS  
PC BOARD ASSEMBLY - POWER BOARD  
ITEM  
REQ'D  
PART NO.  
S20500-7  
DESCRIPTION  
C1,C4,C9,C12  
C2,C3,C10,C11  
C5,C15,C18  
C6,C8,C19  
C7,C21  
C13  
C14,C16  
C17  
)
4
4
3
3
2
1
2
1
1
2
4
13  
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
.047/1600  
4700pF/50  
150pF/100  
.022/50  
27/35  
50/25V  
1.0/35  
18/15  
.27/50  
)
S16668-6  
S16668-9  
S16668-5  
S13490-93  
S13490-83  
S13490-42  
S13490-39  
S13490-130  
S14293-18  
T12705-44  
T12199-1  
)
)
)
)
)
)
)
)
~.04  
)
9.00  
)
)
C20  
CR1,CR2  
D1,D2,D8,D9  
)
)
)
DPST RELAY  
DIODE 1000V/1A  
1N4004  
PRO-CUT 80  
POWER  
G3440-1  
)
)
)
D3,D4,D5,D6,D7,D15,D16,D18  
D20,D21,D22,D23,D24  
DZ1,DZ3,DZ5,DZ6,DZ8,DZ10  
DZ12,DZ13,DZ14  
)
)
)
)
9
)
T12702-29  
1N4744A  
DZ2,DZ4,DZ9,DZ11  
DZ7,DZ15,DZ16  
J10  
OCI1,OCI3,OCI4  
Q1  
)
4
3
1
3
1
4
4
)
)
)
)
)
)
)
T12702-40  
T12702-19  
S20351-6  
S15000-22  
T12704-75  
T12704-73  
S24376-2  
)
)
)
)
)
)
1N4735  
1N4742A  
HEADER  
OPTO ISOLATOR  
FET (SS)  
)
)
)
A 1  
)
Q2,Q3,Q4,Q5  
R1,R2,R3,R4  
)
IC PKG MOSFET (SS)  
40/10W  
)
)
DZ1  
R5,R6,R7,R8,R15,R16,R17  
R18,R33,R37,R54,R55,R56  
R57,R64,R65,R66,R67,R97  
R9,R10,R11,R12,R13,R14,R19  
R20,R21,R22,R58,R59,R60  
R61,R62,R63,R68,R69,R70  
R71  
)
19  
)
)
S19400-1001  
)
1K 1/4W  
DZ3  
R13  
)
20  
10  
S19400-10R0  
)
10 1/4W  
DZ2  
R23,R24,R25,R26,R34,R43  
R51,R53,R98,R107  
)
)
S19400-1503  
)
150K 1/4W  
R27  
)
1
10  
)
S19400-1000  
S19400-2213  
)
)
100 1/4W  
221K 1/4W  
R28,R36,R38,R44,R47,R87  
R88,R96,R118,R119  
R29,R30,R31,R32,R73,R74  
R75,R76,R77,R78,R80,R81  
)
)
)
)
12  
T14648-19  
)
1K 5W  
R35  
)
1
5
1
1
1
3
4
2
4
3
1
1
2
1
2
1
1
1
1
2
1
1
2
1
2
1
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
S19400-3162  
S19400-1002  
S19400-2432  
S19400-5620  
S19400-2801  
S19400-7681  
S19400-6191  
S19400-2001  
S19400-1004  
S19400-2212  
S19400-1822  
S19400-4751  
S19400-3323  
S19400-1652  
S19400-1502  
S19400-1372  
S19400-1821  
S19400-2941  
T12300-79  
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
31.6K 1/4W  
10K 1/4W  
24.3K 1/4W  
562 1/4W  
2.8K 1/4W  
7.68K 1/4W  
6.19K 1/4W  
2.0K 1/4W  
1M 1/4W  
22.1K 1/4W  
18.2K 1/4W  
4.75K  
332K 1/4W  
16.5K 1/4W  
15K 1/4W  
13.7K 1/4W  
1.82K 1/4W  
2.94K 1/4W  
R39,R46,R49,R91,R109  
R40  
R41  
R42  
R45,R48,R94  
R50,R52,R101,R103  
R72,R79  
R82,R83,R84,R85  
R89,R90,R92  
R93  
R95  
R99,R108  
R100  
R102,R110  
R104  
R105  
R106  
R111  
R112,R113  
R114  
R115  
R116,R117  
T1  
X1,X3  
)
)
)
)
)
)
A 2  
R27  
)
)
)
)
)
R23  
R44  
)
)
)
DZ15  
R89  
R40  
R46  
R47  
D15  
R87  
R88  
)
)
)
)
R84  
C21  
)
)
1
WATT  
1
OHM 1% RESISTOR  
)
)
S19400-2211  
S19400-4752  
T10812-41  
S19400-3321  
S13000-46  
)
)
2.21K 1/4W  
47.5K 1/4W  
)
)
10K 1/2W TRIMMER  
3.32K 1/4W  
TRANSFORMER  
IC,LM224,OP-AMP  
IC,431,VOLTAGE REF.  
)
)
)
)
)
)
R93  
)
S15128-4  
S15128-10  
R50  
R82  
X2  
R52  
R43  
R33  
R95  
D4  
CAPACITORS  
RESISTORS  
=
MFD/VOLTS  
A 3  
=
OHMS  
R92  
C16  
D6  
R41  
R42  
R98  
R49  
R48  
D18  
D3  
R37  
R39  
R 5 3  
R104  
R105  
R106  
R99  
DZ8  
DZ10  
R62  
D7  
D23  
R51  
R107  
R108  
DZ9  
C10  
R72  
R79  
R100  
R109  
C20  
R63  
D22  
DZ11  
DZ12  
R119  
DZ13  
R118  
R112  
R113  
R36  
DZ16  
A 4  
C14  
R35  
R76  
R75  
0
3-19-99  
~.04  
3440-1B  
G
0
12.00  
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 pro-  
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the  
machine.  
PRO-CUT 80  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-8  
G-8  
ELECTRICAL DIAGRAMS  
SCHEMATIC - OUTPUT PC BOARD  
( E L E C T R O D E )  
C H O K E  
R 9  
2 2 1 K  
R 5 6  
8 2 5  
1 . 2 1 K  
R 2 4  
R 3 4  
3 . 7 4 K  
R 5 8  
1 . 5 0 K  
R 5 4  
2 . 0 0 K  
R 6 1  
R 2 8  
3 . 7 4 K  
1 . 5 0 K  
4 7 5  
R 3 2  
R 5 9  
5 . 1 1 K  
3 . 3 2 K  
R 2 2  
R 2 6  
2 2 1 K  
R 2 7  
3 . 9 2 K  
R 6 0  
R 7  
3 3 2  
1 0 W 1 6 0  
R 2 1  
R 2 5  
R 2 3  
5 1 1  
R 1  
1 5 W 2 0 0  
5 1 1  
R 3 6  
3 3 2  
R 5 5  
1 . 0 0 K  
1 5 W 2 0 0  
R 3 8  
R 2  
5 1 1  
1 . 2 1 K  
R 1 1  
R 4  
R 6  
1 . 5 0 K  
R 8  
1 . 5 0 K  
4 7 5  
R 3 1  
1 . 2 1 K  
R 1 0  
R 1 2  
3 . 9 2 K  
2 2 1 K  
R 1 3  
R 3  
5 1 1  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
PRO-CUT 80  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-9  
G-9  
ELECTRICAL DIAGRAMS  
PC BOARD ASSEMBLY - OUTPUT BOARD  
REQ'D  
PART NO  
S20500-5  
IDENTIFICATION  
.0015/2000V  
1.0/35  
.0047/3000V  
.1/1000  
ITEM  
C1,C3,C11,C15,C34,C35  
)
6
1
6
4
)
)
)
)
C2  
)
S13490-42  
T11577-58  
S20500-1  
)
C4,C26,C27,C30,C36,C37  
C5,C6,C7,C25  
C8,C12,C17  
C9,C10,C21  
C13  
)
)
)
)
)
)
)
3
)
S16668-7  
820pF/50  
.0047 or .005/1400  
)
3
1
1
1
1
)
)
T11577-52  
S13490-72  
S13490-71  
S13490-93  
S13490-121  
)
)
)
)
)
C14  
C16  
C18  
)
)
)
C20,C22,C23,C24,C29,C38  
)
6
1
)
)
S16668-5  
S16668-11  
)
.022/50  
.1/50  
C28  
)
)
C31,C32  
C33  
CR1  
)
2
1
1
)
)
T11577-46  
T11577-57  
S13929-10  
)
)
)
.05/600V  
0.1/400  
RELAY,DPDT,24VDC  
)
)
)
G3439-1  
C16  
OUTPUT  
X4  
D10,D11,D13,D14,D15,D16  
D17,D19,D20,D21,D23,D25  
D26,D31  
D24  
D18  
R4  
R3  
B12  
B11  
X1  
Q7  
Q8  
D12,D22  
D18,D24  
)
)
2
2
4
4
1
4
1
1
1
1
1
1
2
4
1
)
T12705-34  
T12705-50  
T12705-46  
T12702-29  
T12702-23  
T12702-19  
S20351-6  
S20351-10  
S20351-14  
S20351-4  
)
1N4936  
DIODE  
1000V/3AMP DIODE  
1N4744A  
1N5352B  
1N4742A  
HEADER  
RT. ANGLE HEADER  
HEADER  
HEADER  
HEADER  
5.6mH  
RED LED  
GREEN LED  
OPTOCOUPLER,LOGIC-OUT  
OPTO ISOLATOR  
IC PKG MOSFET (SS)  
HEXFET TRANS. (SS)  
2N4401  
R61  
DZ3  
)
)
D27  
D28  
DZ12  
R59  
D27,D28,D29,D30  
DZ1,DZ2,DZ9,DZ10  
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
R34  
C19  
)
X2  
DZ3  
)
A 1  
DZ7,DZ8,DZ11,DZ12  
)
R30  
J30  
)
J31  
J32  
J33  
J34  
)
)
)
)
OCI1  
Q2  
Q4  
S20351-8  
T12218-2  
T13657-2  
T13657-3  
D9  
L1  
)
LED1,LED2  
LED3,LED4,LED5,LED6  
OCI1  
OCI2,OCI3,OCI4  
Q1,Q3,Q7,Q8  
Q2,Q4  
Q5  
Q6  
R1,R38  
R2  
)
)
LED3  
B21  
)
S15000-26  
S15000-10  
T12704-73  
T12704-80  
T12704-68  
T12704-86  
T12300-47  
S19400-5110  
T12300-66  
T14648-2  
)
)
D25  
D26  
R18  
R19  
)
)
3
)
C10  
R58  
R28  
4
2
1
1
2
1
2
1
)
)
)
)
D22  
D12  
)
D23  
)
)
)
)
)
)
)
)
)
R5  
LED1  
C9  
TRANSISTOR,IGBT,1200V,45A  
Q3  
Q1  
)
15  
511 1/4W  
15W 56 OHM PWR RESISTOR  
25 5W  
W
200 OHM RESISTOR  
Q5  
)
)
)
R22  
D16  
D17  
C18  
R3,R4  
R5  
R6,R8,R28,R58  
)
)
)
)
/
LED6  
R55  
)
)
)
D31  
CR1  
)
4
)
S19400-1501  
1.5K 1/4W  
R2  
DZ9  
C2  
Q6  
D15  
D14  
LED4  
C21  
LED2  
R9,R13,R27  
R10,R11,R24,R29,R62  
R12,R26  
R14,R15,R16,R17,R33  
R18,R19  
R20,R54  
R21  
R22  
R23,R25  
R30  
R31,R32  
R34,R61  
R35  
)
3
5
2
5
2
2
1
1
2
1
2
2
1
S19400-2213  
S19400-1211  
S19400-3921  
S18380-3  
S23995-1  
S19400-2001  
T14649-11  
S19400-3321  
T14650-4  
S19400-4751  
S19400-4750  
S19400-3741  
T14649-4  
)
)
221K 1/4W  
1.21K 1/4W  
3.92K 1/4W  
THERMISTOR,PTC,0.08-0.19 OHMS,1.85A  
SHUNT RESISTOR,.001 OHM,4W  
2.0K 1/4W  
160/10W  
3.32K 1/4W  
15W.,2500 OHM RESISTOR  
4.75K  
DZ10  
DZ2  
A 2  
OCI2  
OCI3  
OCI4  
)
)
)
)
)
)
)
)
)
)
DZ1  
R9  
C8  
C38  
)
)
)
D10  
D1  
)
)
TP2  
TP1  
TP3  
)
)
)
)
C37  
R38  
R1  
)
)
)
)
)
)
)
)
)
J33  
C36  
J30  
)
)
)
)
J31  
J34  
J32  
X2B01  
X40  
B2  
D30  
D29  
C11  
C1  
)
)
475 1/4W  
3.74K 1/4W  
100 10W  
)
)
R50,R51,R52,R53,R65,R66  
R55,R60  
R56  
R57  
R59  
R63  
R64  
TP1,TP2,TP3  
TP4  
TP5  
)
6
2
1
1
1
1
1
3
1
1
1
)
)
)
)
)
)
)
T14650-1  
1500 OHMS, 15 W. RESISTOR  
1K 1/4W  
825 1/4W  
8.25K 1/4W  
5.11K 1/4W  
80 15W  
THERMISTOR,PTC,10 OHMS,400MA  
480V/180J MOV  
)
S19400-1001  
S19400-8250  
S19400-8251  
S19400-5111  
T14650-2  
S18380-9  
T13640-20  
T13640-9  
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
20J  
15J  
T13640-15  
S15018-19  
X1  
)
)
IC,DRIVER,FET,6A  
CAPACITORS  
RESISTORS  
=
=
MFD/VOLTS  
OHMS  
3-19-99  
3439-1  
G
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 pro-  
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the  
machine.  
PRO-CUT 80  
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G-10  
G-10  
ELECTRICAL DIAGRAMS  
SCHEMATIC - DISPLAY PC BOARD  
1
100  
R3  
100  
R4  
1
7
Q1  
3.32K  
R1  
2N4401  
J40  
J40  
J40  
J40  
2
3
4
5
6
7
"READY"  
SIGNAL  
2
4
8
6
14  
13  
9
C1  
2700p  
50V  
+15V  
LED8  
+15V  
3
8
5
COM  
COM  
COM  
COM  
LED9  
5
CONTROL  
POT  
J40  
DZ1  
10V  
1W  
8
10K  
+15V  
LED6  
100  
R7  
100  
R8  
7
6
5
4
3
2
1
7
Q2  
3.32K  
R5  
2N4401  
2
"AIR LOW"  
SIGNAL  
J40  
J40  
2
4
8
6
J40  
C2  
2700p  
50V  
COM  
1
7
AIR SET  
LED7  
+15V  
3
1
5
1
J40  
J40  
1
7
3
11  
100  
R11  
100  
R12  
J40  
J40  
RESET  
2
3
4
5
6
7
Q3  
2
4
8
6
3.32K  
R9  
2N4401  
4
"THERMAL"  
SIGNAL  
12  
LED4  
C3  
2700p  
50V  
+15V  
3
8
5
LED5  
+15V  
4
8
LED3  
7
6
5
4
3
2
1
7
R15  
R16  
Q4  
3.32K  
R13  
75.0  
75.0  
2N4401  
J40  
2
4
8
6
3
2
"SAFETY"  
SIGNAL  
8
13  
12  
11  
6
3
2
1
15  
14  
10  
8
7
5
4
9
J40  
C4  
2700p  
50V  
6
FILENAME: M18920_1AA  
LED2  
LED1  
3
5
1
GENERAL INFORMATION  
ELECTRICAL SYMBOLS PER E1537  
LAST NO. USED  
243  
R20  
1
R- 20  
C-  
DZ-  
1
LED-  
9
5
CAPACITORS =  
RESISTORS Ohms  
DIODES  
MFD  
(
.022/50V  
1/4W  
(UNLESS OTHERWISE SPECIFIED)  
UNLESS OTHERWISE SPECIFIED)  
LABELS  
=
(
UNLESS OTHERWISE SPECIFIED)  
NOTES :  
=
1A, 400V  
SUPPLY  
VOLTAGE NET  
+15V  
N.A. SINCE COMPONENTS OR CIRCUITRY ON  
A
PRINTED CIRCUIT BOARD MAY CHANGE  
POWER SUPPLY SOURCE POINT  
COMMON CONNECTION  
WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY  
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE  
NUMBER.  
J40  
J40  
15  
FRAME CONNECTION  
C5  
EARTH GROUND CONNECTION  
4.7  
35V  
10  
COM  
10-31-97D  
M18920  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
PRO-CUT 80  
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G-11  
G-11  
ELECTRICAL DIAGRAMS  
PC BOARD ASSEMBLY - DISPLAY BOARD  
ITEM  
QTY.  
PART No.  
IDENTIFICATION  
C1,C2,C3,C4  
C5  
DZ1  
4
1
1
S16668-4  
S13490-25  
T12702-27  
2700pF/50  
4.7/35  
1N4740  
LED1  
1
2
2
1
1
1
1
4
4
4
6
2
1
2
1
M18875-1  
M18875-5  
M18875-2  
M18875-6  
M18875-3  
M18875-7  
M18875-4  
T12704-68  
S19400-3321  
S19400-6811  
S19400-1000  
S19400-75R0  
S19400-8250  
S19400-2671  
S19400-2430  
LIGHT BAR,LED,YELLOW  
LIGHT BAR,LED,RED  
LIGHT BAR,LED,RED  
LIGHT BAR,LED,YELLOW  
LIGHT BAR,LED,YELLOW  
LIGHT BAR,LED,GREEN  
LIGHT BAR,LED,GREEN  
2N4401  
3.32K 1/4W  
6.81K 1/4W  
100 1/4W  
75 1/4W  
LED2,LED7  
LED3,LED6  
LED4  
LED5  
LED8  
LED9  
Q1,Q2,Q3,Q4  
R1,R5,R9,R13  
R2,R6,R10,R14  
R3,R4,R7,R8,R11,R12  
R15,R16  
R17  
825 1/4W  
2.67K 1/4W  
243 1/4W  
R18,R19  
R20  
4.00  
1.10  
1.65~.04  
1.40  
LED9  
LED8  
LED6  
LED5  
LED4  
LED3  
R20  
Q4  
LED7  
LED2  
1.00  
LED1  
R8  
R14  
C5  
DZ1  
Q1  
Q2  
Q3  
J 4 0  
.20  
L10721-1  
0
0
4.50~.04  
4.30  
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 pro-  
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the  
machine.  
PRO-CUT 80  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SVM ERROR REPORTING FORM  
We need to know if there are errors in our manuals. We also value any suggestions as to  
additional tests or procedures that would make this SVM a better tool for you.  
If you discover new or different “Problems or Symptoms” that are not covered in the three col-  
umn troubleshooting chart, please share this information with us. Please include the  
machine’s code number and how the problem was resolved.  
Thank You,  
Technical Services Group  
Lincoln Electric Co.  
22801 ST. Clair Ave.  
Cleveland, Ohio 44117-1199  
FAX 216-481-2309  
SVM Number ___________________________  
Page Number if necessary__________________  
Your Company__________________________  
Your Name_____________________________  
Please give detailed description below:  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
SD287 01/99  
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