Lincoln Electric IM595-A manual Routine Maintenance, Periodic Maintenance

D-2 MAINTENANCE D-2

ROUTINE MAINTENANCE

1.Keep the cutting or gouging area and the area around the machine clean and free of combustible materials. No debris should be allowed to collect which could obstruct air flow to the machine.

2.Every 6 months or so, the machine should be cleaned with a low pressure airstream. Keeping the machine clean will result in cooler operation and higher reliability. Be sure to clean these areas:

-Power, Output and Control printed circuit boards and heat sinks

-Power switch

-Main Transformer

-Input Rectifier

3.Examine the sheet metal case for dents or 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.

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.

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.

PERIODIC MAINTENANCE

WARNING

ELECTRIC SHOCK CAN KILL.

• Turn off machine at the disconnect switch on the front of the machine before tightening, cleaning or replacing consumables.

----------------------------------------------------------------------------

Change consumables as required.

1. Thermal Protection

Two thermostats protect the machine from excessive operating temperatures. Excessive temperatures may be caused by a lack of cooling air or operating the machine beyond the duty cycle and output rating. If excessive operating temperatures should occur, the yellow thermal LED will light and the thermostat will prevent output voltage or current.

Thermostats are self-resetting once the machine cools sufficiently. If the thermostat shutdown was caused by excessive output or duty cycle and the fan is operating normally, the Power Switch may be left on and the reset should occur within a 15 minute period. If the fan is not turning or the air intake louvers were obstructed, then the power must be switched off and the fan prob- lem or air obstruction must be corrected.

2.Filter Capacitor Conditioning (PRO-CUT 80, 400- 460 VAC or 460-575 VAC)

A protection circuit is included to monitor the voltage across filter capacitors C1 and C2. In the event that the capacitor voltage is too high, the protection circuit will prevent output. The protection circuit may prevent output providing all these circumstances are met:

a.Machine is connected for 400-460 or 460-575 VAC input.

b.Machine did not have power applied for many months.

c.Machine will not produce output when power is first switched on.

If these circumstances apply, the proper action is to switch the machine on and let it idle for up to 30 min- utes. This is required to condition the filter capacitors after an extended storage time. The protection circuit will automatically reset once the capacitor conditioning and resultant voltage levels are acceptable. It may be necessary to turn the power switch off and back on again after this period.

PRO-CUT 80