Lincoln Electric IM491-B User's Manual
Contents
1. EZD ap 9 i 970 v 9 1 1 1 1 1 g E SSHINN LLVM LLVM NHO SHOLSISHH HOLIMS LESTA NZd S TOSWAS HE 1 TVHSNZO woruao Ston OL 3002 TVNOILVN SI sound HOLIMS IVISONNSHL 1100 Gquvog8 d HOLIMS ANVHINd OL 300 TVOINLO3TH Ston Ston TVNOILVN OL TYNOILYN OL OL ze NOILdO 40 40 gt z Ty gt o2. 125 PLASMA CUTTING POWER SOURCE For use with machines having Code Numbers 10384 thru 10388 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 thought ful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful RETURN TO MAIN MENU 4 _ a 7 2 OPERATOR S MANUAL LINCOLN 8 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 1 491 October 1999 WARNING PLASMA CUTTING or GOUGING can be hazardous PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you pur chase a copy of Safety in Welding amp Cutting ANSI Standard 249 1 from the American Welding Society P O Box 351040 Miami Florida 33135 CSA Standard W117 2 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REP
3. Bushing 14614 1 PIN BN bip NR PIE Nie m 208 m 1 x WI Bushing 32 14614 3 19320 6 12 96 6 12 96 CASE FRONT ASSEMBLY Parts List P 184 D es JE E JE JE JE LLL 2 JL JL 2 2 JL 2 JL JL JL ns JL JL JL JL 2 een eemol eegenen a egen ee ee co JL JL es es ss ss L7713 5 28 93C Description 1 Case Front G1873 1 1 2 Nameplate Domestic L8315 1 2 Nameplate Export L8354 1 3 PC Board Asbly M16301 1 1 Self Tapping Screw 58025 71 4 4 Reset Button 52 T15089 1 5 Run Purge Switch S2 T10800 13 1 6 Potentiometer 1 10812 40 1 7 Spacer 518280 1 8 Knob 10491 1 9 Line Switch Assembly Dual 6 Triple Voltage 16284 1 9 Line Switch Assembly Single Voltage M16284 1 1 12 Pan Head Screw 14731 16 2 13 Hole Plug T10397 20 1 2 5 93 33 INPUT SUPPLY CONNECTION DIAGRAM FOR SINGLE VOLTAGE MACHINE NOTE MACHINES ARE SHIPPED FROM FACTORY CONNECTED GND H LINK FOR 575 VOLTS Do not operate with covers removed Disconnect input power before servicing ee Ene ee Do not touch electrically live parts Only qualified persons should install can Mi use or service this equipment HIGH VOLTAGE 1 CONN
4. Connect the PRO CUT grounding terminal located on the side of the case back to a good electrical earth ground LOCATION Place the PRO CUT where clean cooling air can freely circulate in through the front intake and out through the rear louvers 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 Before plan ning the installation read the section entitled Frequency Interference Protection A source of clean dry compressed air or nitrogen must be supplied to the PRO CUT Oil in the air is a severe problem and must be avoided The supply pressure must be between 80 and 150 psi 551 and 1032 kPa The flow rate is approximately 8 0 cfm 225 l min Failure to observe these precautions could result in excessive operating temperatures or damage to the torch HIGH FREQUENCY INTERFERENCE PROTECTION The PRO CUT employs a solid state high frequency torch starting circuit which drastically reduces high fre quency emissions from the machine as compared with spark gap type high frequency generators Radiated interference can develop however in the following four ways Direct interference radiated from the machine Direct interference radiated from the cutting leads Direct interference radiated from feedback into the power lines 4 Interferenc
5. burning the operator others or even piercing safety clothing 1 j Also see Items 4c and 6 A 2 b 2 6 ARC RAYS can burn 2 a Use safety glasses and a shield with the prop er filter and cover plates to protect your eyes from sparks and the rays of the arc when per forming or observing plasma arc cutting or gouging Glasses headshield and filter lens should conform to ANSI 287 standards Use suitable clothing including gloves made from durable flame resistant material to protect your skin and that of your helpers from the arc rays 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 Apr 93 Where compressed gases are to be used at the job site spe When not cutting or gouging make certain no part of the elec Do not cut or gouge tanks drums or containers until the prop Vent hollow castings or containers before heating cutting or Do nor fuel engine driven equipment near area where plasma FUMES AND GASES 3 a Plasma cutting or gouging may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When cutting or gouging keep your head out of the fumes Use enough ventila tion and or exhaust at the arc to keep fumes and gases away from the breathing zone When cutting or gouging on lead or cadmium plated st
6. 6 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s rec ommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations PLASMA ARC can injure V 4 7 a Keep your body away from nozzle plasma arc 7 0 Operate the pilot arc with caution The pilot arc is capable of burning the operator others or even piercing safety clothing ELECTRIC AND MAGNETIC FIELDS amp may be dangerous 8 a Electric current flowing through any ductor causes localized Electric S Magnetic Fields EMF Cutting or gouging current creates EMF fields around torch cables and cutting machines 8 b EMF fields may interfere with some pacemakers so opera tors having a pacemaker should consult their physician before cutting or gouging 8 c Exposure to EMF fields during cutting or gouging may have other health effects which are now not known 8d All operators should use the following procedures in order to minimize exposure to EMF fields from the cutting or gouging circuit 8 d 1 Route the torch and work cables together Secure them with tape when possible 8 d 2 Never coil the torch cable around your body 8 d 3 Do not place your body between the torch and work cables If t
7. LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN 38 Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspira teur pour les fum es des zones de travail Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fumaca Use ventila o e exhaust o para remover fumo da zona respirat ria 6 9 fsPBHEICTABSSUCFEU CEE LITE R zc EUR E fE SH7IAE S XACE E MASH A8 715 714 Qai ce 44 SU ARA bas A axial e 20 ge ja uc power off before servicing Desconectar el cable de ali mentacion de poder de la maquina antes de iniciar cualquier servicio D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten N o opere com as tampas removidas Desligue a corrent
8. e Sal Xe nisle HIE ola Ju Gu Gi ll el all gual ye eani ag gh la gS DA ule 3 Jio wae Keep flammable materials away Mantenga el material combustible fuera del area de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflam veis bem guarda dos e naedoe6o0o0s cosiTExX REA e i 9 Vi S88 AIX ng Am AL Aal e Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschutz Use prote o para a vista ouvido e corpo HRUBSISUCREREUCT ez 119 Sal Seats s ESSAI due Al lan Gl ysl e 4 READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR
9. tements de protection libres de l huile tels que les gants en cuir chemise paisse pan Avant de faires des travaux l interieur de poste la debrancher talons sans revers et chaussures montantes p l interrupteur la boite de fusibles Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les Garder tous les couvercles et dispositifs de s ret leur place Mar 93 TABLE OF CONTENTS Page Safety 511 19 410 2 4 Introductory Information ss 6 ele ere EE 7 Product DSS ele oec e pa e ERE RR RR RR UNS A RENS 8 Preheat Temperature for Plasma Cutting seem 8 User Responsibility sise 8 gc UEL Le EP rere rr errr rey 9 11 Safety Precautions is 9 LOCATION 9 High Frequency Interference Protection e 9 Electrical Input Connection uci trn evt 10 Air Input Connections EEN sa saga daa 11 Output Cohnectloris eire i 11 Torch CGonpnechon 11 Work Cable and Clamp Installation 11 Operating Instructions ses 11 14 Sequence of events dn ERI HI AM IHE II 11 Pilot Arc Discussion ss 12 Procedure Recommendations enne 12 G n ral See ae EE ee 12 Material Thickness below 75 mm 12 Expanded Metal 13 Material Thickness above 75
10. cylinder away from areas where it may be damaged Never lift equipment with cylinder attached Never allow the cutting torch to touch cylinder Keep cylinder away from live electrical circuits Maximum inlet pressure 150 psig A source of clean compressed air or nitrogen must be supplied to the PRO CUT The supply pressure must be between 80 and 150 psi 551 and 1034 kPa The flow rate is approximately 8 0 cfm Oil in the air is a very severe problem and must be avoided Remove the plastic thread protector from the regulator input port located on the back of the machine Use a suitable gas connection fitting to make the connection to the available air supply The input port is a 1 4 6 3 mm NPT thread Tighten the air fitting to prevent leakage but do not overtighten The use of Teflon tape to seal the connection is recommended Nitrogen from cylinders may be used with this machine The cylinder of nitrogen gas must be equipped with a pressure regulator No more than 150 psi 1034 kPa may be supplied to the regulator on the machine Install a hose between the regulator on the gas cylinder and the gas inlet on the cutter OUTPUT CONNECTIONS A WARNING HIGH FREQUENCY SHOCK CAN CAUSE INJURY OR FALL Keep the cutting torch and cables in good condition Secure yourself in position to avoid a fall Torch Connection The PRO CUT comes factory equipped with a cutting torch Cutting torches come with a 2
11. light on Wait for machine to cool Torch assembly is Light is blinking two short flashes in close 1 Not connected properly succession followed by one second off 2 Damaged period 3 Not designed for use with this machine Check connections repair or replace as needed 20 STATUS LIGHTS CONDITION SUGGESTIONS SAFETY It is possible that this light could turn on when power is first applied to machine The torch assembly is misconnected or damaged The shield cup assembly is not in place While cutting or gouging if the voltage between the nozzle and the work is too high it will put the machine into safety If the cable is punctured or cut it can trip the SAFETY If machine can be reset it is OK to continue operation Check torch connection to machine Securely fasten shield cup assembly in place By pressing reset the machine will be functional This occurs most often when the consumables are wearing out By removing the hafnium that builds up on the inside of the nozzle it is possible to extend the life of the consumables By pressing reset it will clear the SAFETY When cutting is tried again the machine will either go into MALFUNCTION or SAFETY until that time the machine will not indicate a malfunction condition PROCEDURE FOR REPLACING PC BOARDS A WARNING ELECTRIC SHOCK CAN KILL BEFORE PERFORMING ANY MAINTE NANCE THAT REQUIRES OPENING THE CASE OF THE POWER SOURCE Disco
12. mm 13 UMN P C 13 DIESEeCIIK M 14 Suggestions for Extra Utility from the PRO CUT 14 Maintenance Procedures iier e eei RR 15 Routine Maintenance see 15 Troubleshooting 15 22 Troubleshooting 15 19 PRO CUT 125 Status Lights Operating 20 21 Procedure for Replacing P C Boards 22 Parts 4518 42 88 CIR PREVEDE 24 33 Input Supply Connection for Triple Voltage Machine 34 Cutting Torch Connection Diagramme 35 Wiring Diagram PRO CUT 128 36 for selecting a QUALITY product by Lincoln Electric We want you d hank You to take pride in operating this Lincoln Electric Company product eee as much pride we have in bringing this product to you Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your equipment identification information below for future reference This informati
13. preheat temperature may be required The recommended minimum preheat tem perature for plate thickness up to 1 1 4 inch is 70 F USER RESPONSIBILITY Because design fabrication erection and cutting vari ables affect the results obtained in applying this type of information the serviceability of a product or struc ture is the responsibility of the user Variations such as plate chemistry plate surface condition oil scale plate thickness preheat quench gas type gas flow rate and equipment may produce results different than those expected Some adjustments to procedures may be necessary to compensate for unique individ ual conditions Test all procedures duplicating actual field conditions INSTALLATION SAFETY PRECAUTIONS Read the safety precautions at the beginning of this Operator s Manual before proceeding Only personnel that have read and under stood this Operating Manual should install and operate this equipment Machine must be connected to system ground per any national local or other applicable electrical codes The power switch is to be in the OFF position when connecting power cord to input power A WARNING TURN THE INPUT POWER OFF USING THE DIS CONNECT SWITCH AT THE FUSE BOX BEFORE ATTEMPTING TO CONNECT THE INPUT POWER LINES Only qualified personnel should perform this installa tion Turn the power switch on the PRO CUT off before connecting or disconnecting output cables
14. the 62 second postflow time to elapse before attempting to change the elec trode Failure to do so may cause severe dam age to the torch head Suggestions for Extra Utility from the PRO CUT System If it becomes absolutely necessary to cut through a very thick section the air flow at the regulator on the back of the machine may be lowered to get a better result If it is taken too low the power source will trip off until the pres sure is raised back to about 45 psi 311 kPa It is not wise to operate in this manner for long periods of time because the consumable life is severely shortened In some cases where moderate or thin sections are being cut higher air pressure may give bet ter consumable life At pressures about 70 psi 482 kPa the pilot arc may sputter This may be an annoyance but it will not damage the torch or power source 60 psi 414kPa is the minimum recommended pressure to provide proper cooling in all situations Feel free to experiment with higher pressures not to exceed 150 psi 1034 kPa 14 The PRO CUT will cut with consumables that are worn considerably Many competitive sys tems require replacement consumables long before a PRO CUT system does This is because of the solid state current regulation that the PRO CUT has Also the safety reset circuit provides a means of extending nozzle life Sometimes a small piece of material spits from the electrode and bridges the gap between th
15. the best way to keep dross and hot air from burning back into it Do not carry a long arc This may trip the safety or fault circuits and wears consumables rapidly Always hold a 1 4 standoff while cutting Use the proper machine setting Setting the The PRO CUT is capable of operation with a 50 ft 15 2 m plasma torch Pilot arc operation may be slightly degraded with this torch installed Sputtering may occur after the pilot arc is established and occasionally the pilot arc may not light after the trigger is depressed Neither cutting performance nor machine relia bility will be lessened by this condition Keep in mind that the condition of the consumables and air pressure level have a large impact on pilot arc ignition A WARNING ELECTRIC SHOCK CAN KILL Turn off machine at the disconnect switch on the front of the machine before tightening cleaning or replacing consumables machine to maximum output will not produce the best cutting performance in most situations Use proper cutting or gouging procedures referred to in Procedures Guideline Use the nozzle with the largest orifice size that gives an acceptable cut This will improve parts life Never use the 1 1 mm dia or 1 4 mm dia nozzles at outputs above the yellow range The electrode should be finger tight for a snug fit It should not be torqued any more than 38 inch pounds DO NOT USE PLIERS TO OVER TIGHTEN THE ELECTRODE Always allow
16. 2 100 32 100 Idle Current 4 5 amps 220V Idle Power 0 7 kW Maximum Power Factor Rated Load 0 60 Net Weight w 25 ft 7 6 m Cable 480 Ibs 218 2 kg w 50 ft 15 2 m Cable 489 Ibs 222 3 kg Dimensions H x W x D 35 6 x 19 x 22 905mm x 483mm x 559mm includes lift bail and undercarriage Several standard input voltages and options packages are available specified by type number PRODUCT DESCRIPTION The PRO CUT 125 is a constant current single range continuous control plasma cutting system The system is one of the most sophisticated on the market It provides excellent starting characteristics cutting visibility and arc stability The torch has a patented safety mechanism which insures that the consumables are in place before cutting or gouging This is extremely important due to the high voltages involved The PRO CUT 125 comes with an air regulator coarse air filter oil coalescing filter and pressure gauge The machine comes with a 25 ft torch cable or a 50 ft torch cable and a spare parts kit The undercarriage is built in and the unit is shipped assembled except for the handle The machine is capable of cutting with compressed air or nitrogen Nitrogen is used to cut aluminum and other nonfer rous metals The PRO CUT is controlled by a microprocessor based system The machine performs rudimentary self troubleshooting when started which aids in field servicing To enhance safety and p
17. 5 8 Hole Dia T12380 3 Ground lead 511609 16 Lead Grommet 19274 3 Plug Housing P7 518249 4 Torch amp Cable Asbly See P 210 C Cable to Machine Connector 519979 Bulkhead Nut Brass 520148 1 Conduit Lock Nut 14370 3 Grommet 18543 1 Shunt Mounting Bracket Self Tapping Screw 18781 8025 65 Shunt Carriage Bolt Lock Washer Hex Nut Sems Screw Hex Nut 18682 11827 24 T9860 6 1 4 20 10082 12 366 32 NON HENNE ej NUN A OPO tal ta Items Not Illustrated Logo Decal Ground Decal Warning Decal Case Back M11893 3 13260 4 13259 Warning Decal Reg Mtg Bracket Warranty Decal Warning Decal Top of Machine Warning Decal Machine Top Decal 50psi Handle Light Duty Ground Clamp Spare Parts Kit Torch 13086 86 519633 2 519720 18378 13086 104 16381 12033 K881 1 RP RP RPP HP 9 6 93 List 207 0 CASE BACK ASSEMBLY L8348 5 28 93 SE Part Description No 1 Case Back L7753 1 1 2 Fan amp Baffle Asbly Includes M15585 1 Fan 17666 1 Fan Blade M8678 2 1 Fan Motor M8895 5 1 Fan Mounting M14064 1 Self Tapping Screw 58025 70 4 Self Tapping Screw 58025 65 4 3 Grommet 510255 12 1 4 519840 1 Fastener
18. 5 ft 7 6 m or a 50 ft 15 2 m cable Pictures of the torch and the required replacement parts are shown in the parts lists in the back of this manual The ends of the cable to be connected to the power source are unique Follow the applicable instructions given in Figure 2 in the back of this manu al 41 Work Cable and Clamp Installation Attach the work clamp to the work cable per the fol lowing 1 Unplug the machine or turn the power switch to the position 2 Insert the work cable terminal lug with the larger hole through the strain relief hole in the work clamp as shown below 3 Fasten securely with the bolt and nut provided Work cable SCH Work clamp gt OPERATING INSTRUCTIONS Sequence of events A Turn on the line power B Connect the air supply to the machine C Turn the power switch on The green Power On LED should begin to glow The fan should start H the Safety LED is glowing push the Safety Reset button If there is no problem the LED will go off If there is a problem refer to Step F and the Troubleshooting Guide D Set the Purge Run switch to Purge The air should start The Air Pressure LED should be lit Adjust the air regulator so that the pressure gauge reads 60 psi 414 kPa E Set the Purge Run switch to Run The air will continue to run for 60 seconds of postflow If the trigger is activated within the first twe
19. AIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS ELECTRIC SHOCK can kill 1 a The electrode and work or ground circuits are electrically hot when the power source is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands When the power source is operating voltages in excess of 250 volts are produced This creates the potential for serious electrical shock potentially even fatal Insulate yourself from work and ground using dry insulation When cutting or gouging in damp locations on metal frame work such as floors gratings or scaffolds and when in posi tions such as sitting or lying make certain the insulation is large enough to cover your full area of physical contact with work and ground Always be sure the work cable makes a good electrical con nection with the metal being cut or gouged The connection should be as close as possible to the area being cut or gouged Ground the work or metal to be cut or gouged to a good elec trical earth ground Maintain the plasma torch cable and work clamp in good 1 9 1 h safe operating condition Replace damaged insulation Never dip the torch in water for cooling or plasma cut or gouge in or under water When working above floor level protect yourself from a fall should you get a shock 1 i Operate the pilot arc with caution The pilot arc is capable of
20. Button 14659 1 4 5 Pressure Gauge 1 6 Female Elbow 14557 13 1 1 7 92 28 SOLENOID ASSEMBLY Parts List P 207 E 518667 5 Description 1 Hose Nipple Male 14557 11 2 Solenoid 18127 4 3 Pipe Tee T10366 4 Pressure Switch 518638 1 5 Board Plug 14156 1 8 Hex Nipple 11289 3 9 519932 1 10 Solenoid 18127 5 10 27 93 29 Parts List P 184 E REGULATOR AND FILTER ASSEMBLY 518669 1 5 28 93 Description Filter Regulator Asbly M16480 1 Filter Element 50 ID x 1 14 Long M16480 B 1 Panel Mounting Nut M16480 C 1 Oil Coalescing Filter 19865 1 Filter Element 45 ID x 1 16 Long 518637 2 1 Filter Element 56 ID x 1 42 Long 519865 1 Hex Nipple 11289 1 1 Male Elbow 518451 2 1 Hole Plug 12250 1 1 Panel Mounting Nut M16480 C 1 1 8 NPT Allen Head Plug M16480 D 1 10 Pipe Plug 510780 4 1 2 91 9 6 93 30 INPUT BOX ASSEMBLY C5 e i e REAR e VIEW LL NETT e OT D Ou d SS 1 H A D D I D D L gt o i jaci aod 1 1 1 Lee ed L1L2L3 Description Input Box Heat Sink Thread Forming Reconnect Panel Asbly Insulation Plastic Expansion Nut Self Tapping Screw M16365 1 518764 1 514020 7 58025 84 SCR Board Asbly Incl
21. ECT 0 amp W INPUT SUPPLY LINES STUDS MARKED U V amp W ON RECONNECT PANEL 2 CONNECT TERMINAL MARKED a NATIONAL ELECTRICAL CODE TO GROUND PER 3 REMOVE HEX NUTS AND POSITION LINKS AS SHOWN REPLACE AND TIGHTEN ALL HEX NUTS THE LINCOLN ELECTRIC CO CLEVELAND OHIO U S A 17491 FIGURE 1 SINGLE VOLTAGE INPUT SUPPLY CONNECTION DIAGRAM FOR TRIPLE VOLTAGE MACHINE NOTE MACHINES ARE SHIPPED FROM FACTORY CONNECTED FOR 440 OR 460 VOLTS LINK POSITIONS Do not operate with covers removed Disconnect input power before servicing Do not touch electrically live parts Only qualified persons should install con Kill use or Service this equipment HIGH VOLTAGE 1 CONNECT U 6 W INPUT SUPPLY LINES STUDS 2209 30Hz 230 60 2 MARKED U amp W ON RECONNECT PANEL 2 CONNECT TERMINAL MARKED cl TO GROUND PER NATIONAL ELECTRICAL CODE 3 REMOVE HEX NUTS AND POSITION LINKS AS SHOWN REPLACE AND TIGHTEN ALL HEX NUTS THE LINCOLN ELECTRIC CO CLEVELAND OHIO U S A FIGURE 1 DUAL amp TRIPLE VOLTAGE 34 PLASMA TORCH CONNECTION DIAGRAM with covers removed Disconnect input power before servicing FOR LINCOLN Do not touch electrically live parts Only qualified persons should install HIGH VOLTAGE use or service this equipment can k
22. P 210 C 1 2 10 92 Parts List P 207 C GENERAL ASSEMBLY PRO CUT 125 THREE PHASE Drop in photos from P 207 C parts page 26 Description Base GENERAL ASSEMBLY PRO CUT 125 THREE PHASE L8473 Base Support L8472 Foot Thread Forming Screw Caster Thread Forming Screw L8284 9225 26 11124 8 9225 28 Axle T6988 22 Wheel Plain Washer Cotter Pin 517073 4 59262 142 510750 1 Case Front Asbly Self Tapping Screw See P 184 D 58025 65 Left Case Side Not Shown Self Tapping Screw 17745 1 58025 65 Right Case Side Not Shown Self Tapping Screw Access Door L7745 2 58025 65 518763 Roof Not Shown Self Tapping Screw L7662 58025 65 Cover Seal Not Shown 12934 Case Back Asbly Self Tapping Screw Access Door See P 207 D 58025 65 16380 Regulator amp Filter Asbly Self Tapping Screw Mounting Bracket See P 184 E 58025 65 518579 Solenoid Asbly Sems Screw Flex Tube Short Flex Tube Medium Flex Tube Long See P 207 E 10082 27 10642 192 10642 193 10642 194 1 2 3 4 5 6 7 8 9 10 11 12 13 14 14 Transformer amp Lift Asbly Dual 6 Triple Voltage Transformer Asbly Dual amp Triple Voltage Lift Bail Transformer amp Lift Bail Asbly Single Voltage Resistor R3 Self Tapping Screw Resistor Mounting B
23. ain the bright pilot arc for long periods of time the machine will go into pilot arc duty cycle limit This is a 20 seconds out of 80 seconds pilot duty cycle The pilot arc is dis abled in the limit period Pilot arc duty cycle limit is indicated by alternately flashing OUT PUT and MALFUNCTION LED s Placing a thin piece of scrap sheet metal above the area to be cut and cutting through both can make the job easier Do not allow cable or body to contact hot sur face Material Thickness above 75 19mm Output set above mid range The best quality and consumable life will be obtained by holding the torch nozzle off the sur face about 1 4 6 4mm Do not touch the noz zle to the work or carry a long arc Use either 519972 standoff guide or 519973 and 519974 contact attachments to protect the torch The only reason not to use these are in special tight corners Always hold at least a 1 4 6 4mm standoff in those situations Set the current to the minimum necessary to make the cut Pierce the plate by slowly lowering the torch onto it at an angle of about 307 to blow the dross away from the torch tip and slowly rotate the torch to a vertical position as the arc becomes deeper 13 Where possible start the cut from the edge of the workpiece Keep moving A steady speed is necessary Do not pause Do not allow the torch cable or body to contact hot surfaces For thicknes
24. be prepaid with charge check or money order in U S Funds IPrices include shipment by 4th Class Book Rate for U S A Mainland Only Please allow up to 4 weeks for delivery IUPS Shipping for North America Only All prepaid orders that request UPS shipment please add 5 00 For order value to 49 99 For order value between 50 00 amp 99 99 For order value between 100 00 amp 149 00 510 00 15 00 For North America invoiced orders over 550 00 amp credit card orders if UPS is requested it will invoiced or charged to you at cost Outside U S A Mainland order must be prepaid in U S Funds Please add 2 00 per book for surface mail or 15 00 per book for air parcel post shipment IMETHOD OF PAYMENT Sorry C O D Orders CHECK ONE 1 1 Please Invoice only if order is over 50 00 1 CT Check Money Order Enclosed U S Funds only creditcad 0 oO Ga USE THIS FORM TO ORDER 5 FREE INFORMATIVE CATALOGS Lincoln Welding School mes Price Code Quantity Cost ED 80 New Lessons in Arc Welding Seminar Information Procedure Handbook Twelfth Edition 45 How to Read Shop Drawings Educational Video Information O Incentive Management HERE ED A New Approach to Industrial Economics e Lames Lincoln Arc Welding The American Century of John C Lincoln Foundation Book Information Welding Preh
25. e nozzle and the electrode In a competitive unit this would often result in the destruction of the electrode and nozzle due to overheating This will result in the tripping of the PRO CUT safety circuit When this happens turn the power off remove the nozzle and scrape any debris from its inside cavity with a piece of sturdy wire or a suitable drill bit Replace the nozzle turn on the power and continue cutting Gouging nozzles may be made from worn cut ting nozzles by drilling the orifice out to 125 3 2mm Use a 1 8 or 31 drill bit Take care to center the hole and be careful because the cop per nozzle may seize to the drill bit Use of the nozzle with the largest orifice size that produces acceptable cutting results will maximize consumable life Smaller orifice sizes constrict the arc more raising the energy densi ty and the temperature Larger orifice sizes have the opposite effect Small orifice nozzles run hotter and wear faster than large orifice noz zles but produce a finer cut with less kerf width There is a certain current where each orifice size becomes unstable because it runs too hot Never use the smallest 043 1 1 mm orifice size at outputs above the yellow range because it will be quickly destroyed MAINTENANCE PROCEDURES A WARNING ELECTRIC SHOCK CAN KILL BEFORE PERFORMING ANY MAINTE NANCE THAT REQUIRES OPENING THE CASE OF THE POWER SOURCE Disconnect input power to this machine at the Discon
26. e antes de fazer servico toque as partes el tricas nuas e X7TTL 2A 9 AVCWRUPD PRE EFFERIA vF BPTF e HEBES e Meg ett Als Aie Jl ale Do not operate with panel open guards off No operar con panel abierto guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen Mantenha se afastado das partes moventes opere com os paineis abertos ou guardas removidas Ro 40 Yel HAE Abiyi calls UN lla Ja e Al Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese Japanese ZS BIR LEIA E COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PR TICAS DE SEGURANCA DO EMPREGADOR SRM OBHOX HD OHRBEE lt K MA CL TRHORERME CF eU RA ET MEL RE Rr de AIMS HAA Sei HAS APSA BHC Aal d aul 24 AAL Gail ag ls Gras L 39 LINCOLN B World s Leader in Welding and Cutting Products Sales and Se
27. e from reradiation of pickup by ungrounded metallic objects Keeping these contributing factors in mind installing equipment per the following instructions should mini mize problems 1 Keep the machine power supply lines as short as possible 2 Keep the work and torch leads as short as possi ble and as close together as possible Lengths should not exceed 50 15 2 m Tape the leads together when practical Be sure the torch and work cable rubber cover ings are free of cuts and cracks that allow high frequency leakage 4 Keep the torch in good repair and all connections tight to reduce high frequency leakage 5 Keep all access panels and covers securely in place NOTE The machine frame MUST also be grounded see paragraph under Input Connection The work terminal ground does not ground the machine frame When the machine is enclosed in a metal build ing several good earth driven electrical grounds around the periphery of the building are recommended 6 Failure to observe these recommended installation procedures may cause radio or TV interference prob lems and result in unsatisfactory cutting or gouging performance resulting from lost high frequency power ELECTRICAL INPUT CONNECTION A WARNING ELECTRIC SHOCK can kill Disconnect input power before proceeding Have a qualified electrician make the input connections Be sure the voltage phase and frequency of the input power is as
28. eat Calculator p Oe Pipe Welding Charts TOTALCOST pocootvo 1111111111 LL Order from BOOK DIVISION The Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 Telephone 216 383 2211 or for fastest service FAX this completed form to 216 361 5901 Name Address Telephone Signature as it appears on Charge Card rer um qum purum mr uM ur TE 37 Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese Japanese BIR Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes los electrodos bajo carga con piel moja da Aislese del trabajo de la tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden N o toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da pe a e terra XuiiHMIIt ELE ebtaer NTUSHIELTFSU 94 d TH
29. eel and other metals or coatings which produce highly toxic fumes keep expo sure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventila tion In confined spaces or in some circumstances out doors a respirator may be required Additional precau tions are also required when cutting or gouging on gal vanized steel dangerous XN Do not use plasma arc cutting or gouging 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 Gases used for plasma cutting and gouging can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe 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 employ er s safety practices CUTTING SPARKS d cause fire or explosion 4 a Remove fire hazards from the plasma cut ting or gouging area If this is not possible cover them to prevent the cutting or gouging sparks from starting a fire Remember that welding sparks and hot materials from plasma cutting or gouging can easily go through small cracks and openings to adjacent areas Avoid cutting or goug
30. em Check the torch cable to see if it is cut or punctured Replace Turn off the machine and turn it back on If the FAULT LED will not stay off when you try to cut again and there is no problem with the torch then something has failed in the machine and the machine should not be left on 4a Check electrode to pilot for short 4b Check the SCR board Replace if bad 4c Check operation of contactors Replace if bad 5 Replace Control PC board Alternating A IR MALFUNCTION LED lights 1 Replace Control PC board Air pressure cannot be set to 60 psi 414 kPa or the Watch the pressure gauge during pilot mode machine cuts poorly through thick sections The air pressure should start as 60 psi 414 kPa and be reduced significantly when the trigger is pulled If not then there is a problem with the solenoid assembly 18 The SAFETY LED is lit The OUTPUT ON and MALFUNCTION LED s blink in alternating order Airflow will not shut off No OCV when 2 and 4 are closed 19 The machine will not operate The machine senses that the shield cup is not in place or the operators could be exposed to dangerous voltages if the machine were allowed to operate Check the shield cup to be sure it is tightly in place Check the torch consumables to see if they are melted together or are simply touching each other Tighten clean or replace See Suggestions
31. ent passing through lifting chains crane cables or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail CYLINDER may explode if damaged 5 a Use only compressed gas cylinders contain ing the correct gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and main tained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Cylinders should be located Away from areas where they may be struck or subjected to physical damage A safe distance from plasma cutting or gouging arc weld ing operations and any other source of heat sparks or flame 5 d Never allow any part of the electrode torch or any other electrically hot parts to touch a cylinder 5 e Keep your head and face away from the cylinder valve outlet when opening the cylinder valve 5 f Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use 5 g Read and follow the instructions on compressed gas cylin ders associated equipment and CGA publication PL Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 9 FOR ELECTRICALLY powered equipment
32. es and examples develop the reader s ability to visualize mechanically drawn objects as they will appear in their assembled form 187 pages with more than 100 illustrations Size 8 1 2 x 11 Durable cloth covered board binding 4 50 postage paid U S A Mainland There is a 10 discount on all orders of 50 00 or more for shipment at one time to one location New Lessons in Arc Welding Lessons simply written cover manipulatory techniques machine and electrode characteristics related subjects such as distortion and supplemental information on arc welding applications speeds and costs Practice materials exercises questions and answers are suggested for each lesson 528 pages well illustrated 6 x 9 size bound in simulated gold embossed leather 5 00 postage paid U S A Mainland Need Welding Training The Lincoln Electric Company operates the oldest and most respected Arc Welding School in the United States at its corporate headquarters in Cleveland Ohio Over 100 000 stu dents have graduated Tuition is low and the training is hands For details write Lincoln Welding School 22801 St Clair Ave Cleveland Ohio 44117 1199 and ask for bulletin ED 80 or call 216 383 2259 and ask for the Welding School Registrar Lincoln Welding School BASIC COURSE 5 weeks of fundamentals lt lt 4 5700 00 lOrders of 50 or less before discount or orders outside of North America must
33. for Extra Utility from the Pro Cut System Check the torch cable to see if it is cut or punctured Replace Check to see that the torch is hooked to the machine properly Push the SAFETY RESET button the LED should go out This circuit rarely trips on power up or because of noise If the circuit can be reset it is OK to continue operation Replace Control PC board as this is a safety problem The pilot arc duty cycle has been exceeded The machine will cool down and the lights will quit blinking in about 10 seconds The pilot arc is limited to 20 out of 80 seconds except in special circumstances such as cutting expanded metal See the section on expanded metal in the Operating Section Check harness 1J7 332 and 3J7 333 24VAC auxiliary supply Replace Control PC board Check 230 VAC across CR1 250V SCR PC board positive negative Check across 31 32 for 110 VAC Replace Control PC board PRO CUT 125 STATUS LIGHTS OPERATING MODES STATUS LIGHTS CONDITION SUGGESTIONS MACHINE ON Should always be on when machine is on OUTPUT ON On when there is voltage potential at the Normal torch cutting or pilot OUTPUT ON is blinking alternately with AIR PRESSURE when power is first There is a problem with the microprocessor applied to machine replace the Control PC board If OUTPUT ON is blinking alternately with MALFUNCTION the pilot arc duty cycle is exceeded Wait for machine light
34. he torch cable is on your right side the work cable should also be on your right side Connect the work cable to the workpiece as close as possible to the area being cut or gouged Do not work next to cutting power source Apr 93 PRECAUTIONS DE SURETE Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher met allique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonc tionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tensi
35. ill ELECTRIC TORCHES MOLEX CONNECTORS LOCK NUT CORD GRIP CONNECTOR 7 DISCONNECT INPUT POWER TO THE PRO CUT AND TURN MACHINE POWER SWITCH OFF INSERT TORCH CABLE THROUGH CASE FRONT OPENING USE LOCK NUT TO MOUNT CORD GRIP CONNECTOR CONNECT PILOT LEAD PLACE GAS LINE FITTING ON ADAPTER AND SCREW TIGHT ATTACH MOLEX CONNECTORS THE LINCOLN ELECTRIC CO CLEVELAND OHIO U S A 519934 FIGURE 2 35 Jequunu epoo y ane 10 queuniedeg 2 sr eu Uu sjaued y JO euo UO y apisul si 401 5 Jenueui siy paleAoo IS 10 93e1n22e jou 3 A uo 10 S siu 3 10N 92011 86058284 ATAYA NO LNSSSHG 10N on xuon M HL 21 HOUOL 886 ese LOTIA HTZZON 805 9 gt eu OL SIDENNOD NId V N 1 Sg NOILOSNNOD 1 09 A0vv 08t 0zZ i i ET 1 H sos 40 IQIS LNSNOdWOD ALIAVO
36. ing PC board corrects problem return it to the local Lincoln Electric Field Service Shop 22 NOTES 23 Parts List P 210 C PCT 125 AMP PLASMA TORCH 2 10 92 125 AMP PLASMA TORCH Description Mag PCT 125 Torch amp Cable 25 Mag PCT 125 Torch amp Cable 50 K880 2 Cable Asbly 25 Cable Asbly 50 L9371 1 L9371 2 Handle Repair Kit Handle LH Includes Handle Nut Handle RH Includes Pan Handle Screw 46 32 x 75 521087 518773 518825 1 Torch Head O Ring Shield Cup O Ring Handle L8680 L8680 B L8680 A Electrode 519962 4 Nozzle Cutting 055 1 4mm Orifice Cutting 067 1 7mm Orifice Cutting 075 1 9mm Orifice Gouging 118 3 0mm Orifice 519961 2 519961 3 519961 4 519961 5 Shield Cup Asbly 519964 3 4 5 6 7 Trigger Asbly 18932 Swirl Ring 519963 Standoff Guide 19972 Gouging Attachment 19975 Contact Cutting Insulator 519973 Contact Cutting Attachment 19974 Tool Box 19576 2 BIN Options Spare Parts Kit Cutting 055 1 4mm Orifice Cutting 067 1 7mm Orifice Cutting 075 1 9mm Orifice Gouging 118 3 0mm Orifice Electrode Swirl Ring O Ring Shield Ring Standoff Guide 25 K881 1 519961 2 519961 3 519961 4 519961 5 519962 519963 18680 519972 Parts List
37. ing near hydraulic lines Have fire extinguisher readily available cial precautions should be used to prevent hazardous situa tions Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equip ment being used trode circuit is touching the work or ground Accidental con tact can cause overheating and create a fire hazard er 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 gouging They may explode cutting or gouging 4 4 Sparks and spatter are thrown from plasma arc Wear safety glasses ear protection and oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when cutting or gouging out of position or in confined places Always wear safety glasses with side shields when in a cutting or gouging area Connect the work cable to the work as close to the cutting or gouging area as practical Work cables connected to the build ing framework or other locations away from the cutting or gouging area increase the possibility of the curr
38. lacing consumables Change consumables as required 15 TROUBLESHOOTING PROCEDURES A WARNING ELECTRIC SHOCK CAN KILL BEFORE PERFORMING ANY MAINTE NANCE THAT REQUIRES OPENING THE CASE OF THE POWER SOURCE Disconnect input power to this machine at the Disconnect switch Do not touch electrically live parts or internal wiring Only qualified personnel should service this machine HOW TO USE THIS GUIDE Carefully read through each applicable section listed on the following pages Remember that most problems are caused by improp er setup such as switch settings control settings etc If you believe the set up is correct and the trouble still exists first check for the obvious input power blown fuses loose PC board connectors broken wires and the like The sections listed on the following pages are intended to help you find the less obvious sources of trouble TROUBLESHOOTING GUIDE Visual Inspection Clean interior of machine with a low pressure airstream Make a thorough inspection of all compo nents Look for signs of overheating broken leads or other obvious problems Many problems can be uncovered with a good visual inspection After the visual inspection proceed to the proper symptom section of this guide for necessary checks to perform LED s light when the power switch is turned Check the input power to be sure it is on Check the power line fu
39. lve seconds the pilot arc will immediately start After twelve seconds a double trigger pull is required to start the arc The second trigger pull must follow the first within one second to start the pilot arc When ready to cut place the work lead piece to be cut place the torch near the work make certain all safety precautions have been taken and pull the trigger 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 The Output ON LED will light The pilot arc will run for 1 8 seconds and shut off unless the plasma is brought in contact with the work and the arc is transferred When the arc is transferred cutting begins When finished cutting release the trigger G When the trigger is released the arc will stop The air will continue to run for 60 seconds of postflow If the trigger is activated within the first 12 seconds the pilot arc will immediately restart After twelve seconds a double trigger pull is required to start the arc The second trig ger pull must follow the first within one second to start the pilot arc If the Safety LED lights at any time check the following WARNING EN ELECTRIC SHOCK CAN KILL 2 Turn off machine at the disconnect switch at the back of the machine before tightening cleaning or replacing consum ables Check the assembly of
40. nect switch Do not touch electrically live parts or internal wiring Only qualified personnel should service this machine ROUTINE MAINTENANCE 1 Keep the cutting or gouging area and area around the machine clean and free of com bustible materials No debris should be allowed to collect which could obstruct air flow to the machine 2 Every few months blow the dust off the air intakes and louvers with compressed air 3 Check the air regulator filters to be sure they do not become clogged The first stage of the air filter on the machine is self draining and will stop most of the water in the air line The sec ond stage of the filter is also self draining and will stop almost all of the oil in the line as well as particulate matter Both stages will drain auto matically when the flow rate changes rapidly 4 Check the filter elements every several months to see if they are clogged weekly in very dirty environments Replace if necessary 9 Inspect the cable periodically for any slits puncture marks in the cable jacket Replace if necessary 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 WARNING ELECTRICAL SHOCK CAN KILL Turn off machine at the disconnect switch at the back of the machine before tightening cleaning or rep
41. nnect input power to this machine at the Disconnect switch Do not touch electrically live parts or internal wiring Only qualified personnel should service this machine Before replacing a PC board which is suspected of being defective visually inspect the PC board in ques tion for any damage to any of its components and conductors on the back of the board If there is no visible damage to the PC board install a new one and see if this remedies the problem If the problem is remedied reinstall the old PC board to see if the problem still exists If it does no longer exist with the old PC board 1 Check the PC board harness conductor pins for corrosion contamination or looseness 2 Check leads in the plug harness for loose or intermittent connection If PC board is visibly damaged electrically compo nents burned copper traces opened or damaged before possibly subjecting the new PC board to the same cause of failure check for possible shorts opens or grounds caused by 1 Frayed or pinched lead insulation 2 Poor lead termination such as a poor contact or a short to adjacent connection or surface 3 Two or more leads shorted together 4 Foreign matter or interference behind the PC boards If PC board is visibly damaged mechanically such as a part vibrated off or was crushed inspect for cause then remedy before installing a replacement PC board If there is damage to the PC board and if replac
42. on can be found on your machine nameplate Model Name amp Number Code amp Serial Number Date of Purchase Whenever you request replacement parts for or information on this equipment always supply the information you have recorded above Read this Operators Manual completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection The level of seriousness to be applied to each is explained below WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment SPECIFICATIONS Type K1394 and K1395 K880 1 25Ft 7 6m Cable amp K880 2 50Ft 15 2m Cable Magnum PCT 125 Air Cooled Torch Input Frequency 50 or 60 Hz Output Rating 125 Amps 148 volts 60 Duty Cycle 110 Amps 140 volts 8096 Duty Cycle 100 Amps 135 volts 10096 Duty Cycle Pilot Current 26 amps Pilot Duty Cycle 25 20 seconds out of 80 seconds Current Range 50 125 Amps Maximum 10 High Input 357 Normal OCV 325 Input Power tandard Voltages 230 460 3 50 60 220 380 440 3 50 60 575 3 60 101 49 60 102 59 51 60 40 60 95 44 0 80 87 54 45 80 33 80 88 40 100 81 49 4
43. on entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie du corps Un coup d arc peut plus qu un coup de soliel donc zones ou pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie aux tincelles Quand on ne soude pas poser la pince a une endroit isol de la masse Un court circuit accidental peut provoquer un chauf fement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de levage cables de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis e
44. oved from the work General Follow safety precautions as printed inside the operating manual and on the machine Either the 519972 standoff guide or 519973 and 519974 contact attachments are recom mended for all cutting applications to protect the torch from dross and improper arcing condi tions Use proper cutting or gouging procedures referred to in procedures guideline Material thickness below 75 19mm Output set below mid range Do not allow the torch cable or body to contact hot surfaces The best cut quality is obtained by reducing the current to a level that is adequate for the maxi mum travel speed Aluminum copper and other nonferrous metals typically require more current than the same thickness of steel For thickness below 75 19mm use an 19961 2 nozzle 1 4mm dia orifice The 519972 standoff guide should be set in the low est position for maximum standoff Expanded Metal Output set near mid range Cut it as you would light gauge sheet metal Expanded metal is pilot arc intensive After about 30 seconds of cutting the pilot arc will change from a bright continuous arc to a discon tinuous one which will sputter slightly It will stay in this mode as long as metal has been cut in the previous 5 seconds If metal is not cut in the previous 5 seconds the arc will shut off and the machine will go into postflow elf the trigger is continuously pressed and released to obt
45. racket Set 20942 L9318 10227 47 L9445 510404 106 58025 87 15137 2 Resistor 82 85 Self Tapping Screw Resistor Mig Bracket Set Resistor Round Head Screw Insulator 510404 104 58025 65 15137 3 510404 45 10 24 7 50 T4479 A Choke amp Right Wheel Well Asbly Choke Asbly Right Wheel Well Thread Forming Screw Self Tapping Screw L8379 M16389 L8431 2 9225 8 8025 65 Choke amp Left Wheel Well Asbly Choke Asbly Left Wheel Well Thread Forming Screw Self Tapping Screw L8381 M16389 L8431 1 9225 8 58025 65 WIN RP BNP BIE BRP BR ND OREO BIR nm P7 27 Description Insulation For Wheel Wells Fastener Button Parts List P 207 C 1 518746 1 14659 AN High Freq Board Asbly Self Tapping Screw See P 207 G 58025 70 Control Panel Thread Forming Screw L7669 1 59225 8 Input Box Asbly Self Tapping Screw See P 207 F 58025 65 Control PC Board Asbly Plastic Expansion Nut Self Tapping Screw PC Board Stand Off G2215 2 14020 3 8025 71 519300 3 By Pass PC Board Asbly Plastic Expansion Nut Self Tapping Screw Self Tapping Screw M16939 1 14020 3 8025 71 58025 70 Bulkhead Asbly Self Tapping Screw M15604 1 58025 70 Bushing 1 1 8 Hole Dia 14614 1 Bushing 1 3 8 Hole Dia 12380 8 Bushing
46. rotection the 60 second postflow period is monitored During the first 12 sec onds of postflow the pilot arc may be initialized with a single trigger pull After 12 seconds the trigger must be pulled twice to start the pilot arc The second trig ger pull must follow the first within 1 second to initiate the arc This prevents accidental starting if the plasma torch is resting in such a manner that the trigger is depressed The postflow time is reset only if the pilot arc is initialized Special control circuitry detects when the nozzle is touched to the workpiece If the nozzle is touched to the workpiece the machine output is instantaneously reduced which protects the consumables When the nozzle is removed form the workpiece the output will return to the set level This feature protects the con sumables from accidental damage when cutting at high currents PREHEAT TEMPERATURE FOR PLASMA CUTTING Preheat temperature control is recommended for opti mum mechanical properties crack resistance and hardness control This is particularly important on high alloy steels and heat treated aluminum Job con ditions prevailing codes alloy level and other consid erations may also require preheat temperature con trol The recommended minimum preheat tempera ture is a starting point Higher temperatures may be used as required by the job conditions and or prevail ing codes If cracking or excessive hardness occurs on the cut face higher
47. rvice 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
48. s between 75 19mm and 1 00 25 4mm use an 819961 4 nozzle 1 9mm dia orifice The 519972 standoff guide should be in the lowest position for maximum standoff For thickness above 1 00 25 4mm use an 19961 4 nozzle 1 9mm dia orifice The 519972 standoff guide should be in the lowest position for maximum standoff Gouging Output set to maximum Use a gouging nozzle S19961 5 The pilot arc may sputter while gouging but this is normal Use the 819975 gouging attachment in the low est position for maximum standoff Bring the torch slowly towards the work at about a 30 angle as if piercing the plate Blow the molten metal away from the torch Do not touch the nozzle to the work To obtain deeper penetration when gouging lower the flowing air pressure to 50 psi To obtain shallower penetration raise the flowing air pressure to 70 psi This process will blow a lot of molten metal and dross BE CAREFUL Blow the dross away from the torch away from the operator and away from flammable objects Do not allow the torch cable or body to contact hot surfaces Performance is similar to air carbon arc gouging with a 1 8 3 2mm carbon electrode In Cases Do not pause when cutting or gouging the metal This is not necessary and causes opera tional difficulty Pausing at the edge of the work piece causes poor consumable life and erratic operation Always position the torch in
49. s plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 PR CAUTIONS DE S RET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du rayon nement de l arc et des projections quand on soude ou quand on regarde l arc b Porter des v tements convenables afin de prot ger la peau Relier la terre le chassis du poste conformement au code de de soudeur et des aides contre le rayonnement de l arc p l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre c Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v
50. s to stop blinking AIR PRESSURE On whenever the air pressure is above 45 Normal conditions are purge preflow psi 311 kPa there is an error condition postflow and cutting mentioned above where air will turn on The air will turn on for a brief time when power is first applied to machine THERMAL Should normally be off If on wait for machine to cool down Machine will cool faster if left on with output off MALFUNCTION Light on At end of preflow machine Check consumables replace as needed checks to see if the torch is shorted and if Check torch cable to see if it is punctured it can fire the SCR s or cut Light blinking If cutting tried with air No air connected to machine air pressure pressure less than 45 psi 311 kPa then set too low or air leak in system the machine will wait for air pressure to become greater than 45 psi 311 kPa Light blinking alternately with OUTPUT Pilot arc duty cycle has been exceeded ON Wait for machine lights to stop blinking Light started blinking during cutting or If cutting or gouging with standoff more than gouging There is an overcurrent condition 1 4 6 4mm caused by a surge of current the machine at high range of machine and nozzle is was not designed to handle Release the accidentally touched to work shorten stickout trigger and resume cutting or gouging or use drag cup Check consumables to see if electrode melted to nozzle Light blinking with THERMAL
51. ses and machine connection Replace line switch The MACHINE ON LED is lit but there is no Check the SAFETY LED If it is lit check the response when the trigger is pulled torch consumables and press the SAFETY RESET button Check the air supply to the machine If the air does not flow the machine will not start Check the operation of the air solenoid by switching the machine to PURGE If the pressure is sufficient the air should begin to flow and the AIR PRESSURE LED should turn on Return to RUN mode If air does not flow check the solenoid by applying 115 VAC to its input leads If it is not bad replace PC board Low air pressure also results in a no start condition AIR PRESSURE LED must be lit when air is flowing 12 seconds or more of postflow time has elapsed and a double trigger pull is required to start the pilot arc The second trigger pull must follow the first within 1 second to start the pilot arc 16 The air begins to the OUTPUT ON LED lights for a brief period but no arc is established The arc starts but sputters badly The THERMAL LED is lit The MALFUNCTION LED is blinking The MALFUNCTION LED is blinking two short flashes in close succession followed by a one second off period 17 Check the torch consumables to be sure they are in tight not dirty or greasy and in good
52. shape Replace the consumables if necessary Check that CR2 engages Blow off the components in the upper compart ment with compressed air Check pilot to 391 for 1 5 ohm resistance Check both 3 ohm 300 watt resistors Replace Control PC board Check the torch consumables to be sure they are tight not dirty or greasy and in good shape Replace if necessary Check air supply for oil or a great deal of water If there is oil or a great deal of water the air must be filtered or the machine switched to nitrogen or bottled air Check air pressure It should be set to 60 psi 414 kPa while air is flowing The machine is overheated Allow it to cool and reset The air intakes of the machine must not be blocked or this will become a nuisance Machine will cool much faster if left on with output off The torch connected to the machine is not connected properly or has been damaged Check all connections and look for sign of damage to the assembly The connected torch is not designed for use with this machine see Specifications Summary for listing of valid torches for this machine The MALFUNCTION LED is lit The FAULT circuit monitors the torch to see if it is shorted as well as internal machine failures Check the torch consumables to see if they are melted together or are simply touching each other Tighten clean or replace See Suggestions for Extra Utility from the PRO CUT Syst
53. specified on the machine nameplate Before starting the installation check with the local power company if there is any question about whether your power supply is adequate for the voltage amperes phase and frequency specified on the rear machine nameplate Also be sure the planned installa tion will meet the U S National Electrical Code and local code requirements Use a three phase power supply fused with the rec ommended super lag fuses Choose an input and grounding wire size according to local codes or use the table below Delay type circuit breakers also called inverse time or thermal magnetic which have a delay in tripping action that decreases as the magnitude of the current increases may be used in place of fuses Using fuses or circuit breakers smaller than recommended may result in nuisance tripping from machine inrush currents even if not cutting or gouging at high currents Models that have multiple input voltages specified on the rear nameplate e g 230 460 are shipped con nected for the higher voltage If the machine is to be operated on the lower voltage it must be reconnected according to the instructions on the inside of the removable panel in the center of the rear panel Electrical supply lines enter the machine next to the removable panel A WARNING ELECTRIC SHOCK can kill Make certain that the input power is electrically disconnected before removing the screws that hold
54. t 1 ar NOILdO LIN SOVANSINI Se ac moron TK Gesten TYNOILAO DS 40 1 EOS a E OL NET On 5 s EE 44100 i Dj d soa 4 1 00227022 SZT gt ONIAIM 36 Now Available 12th Edition The Procedure Handbook of Arc Welding With over 500 000 copies of previous editions published since 1933 the Procedure Handbook is considered by many to be the Bible of the arc welding industry This printing will go fast so don t delay Place your order now using the coupon below The hardbound book contains over 750 pages of welding information techniques and procedures Much of this material has never been included in any other book A must for all welders supervisors engineers and designers Many welding instructors will want to use the book as a reference for all students by taking advantage of the low quantity discount prices which include shipping by 4th class parcel post 15 00 postage paid U S A Mainland How To Read Shop Drawings The book contains the latest information and application data on the American Welding Society Standard Welding Symbols Detailed discussion tells how engineers and draftsmen use the short cut language of symbols to pass on assembly and welding information to shop personnel Practical exercis
55. the removable rear panel in place 9 Have a qualified electrician connect the input leads to U V of the reconnect panel in accordance with the U S National Electrical Code all local codes and the connection diagram located on the inside of the cover The frame of the machine must be grounded A ground terminal marked with the symbol 2E located at the left side of the input box is provided for this pur pose See the U S National Electrical Code for details on proper grounding methods Follow other grounding instructions per the paragraph under High Frequency Interference Protection On triple voltage input machines be sure the recon nect panel is connected per Figure 1 in the back of this manual for the voltage being supplied to the machine A CAUTION Failure to follow these instructions can cause imme diate failure of machine components The PRO CUT is shipped connected for the highest nameplate input voltage Reconnect the power straps to their respective terminals corresponding to the input voltage used RECOMMENDED WIRE SIZE FOR PRO CUT INPUT CONNECTIONS Based on 1993 U S National Electric Code Wire Size Copper 75 Input Voltage Hz 3 Input Wires 1 Grounding Wire 230 60 460 60 220 50 60 380 50 60 440 50 60 Fuse Size AIR INPUT CONNECTIONS A WARNING CYLINDER may explode if damaged Keep cylinder upright and chained to a fixed support Keep
56. the torch consumables If they are not properly in place then machine will not start Check the conditions of the inside of the nozzle If debris has collected scrape it out with a piece of sturdy wire or a suitable drill bit Refer to Suggestions for Extra Utility from the PRO CUT system After the problem is found reset the machine by pressing the Safety Reset button It is possi ble for electrical noise to trip the safety circuit on rare occasions This should not be a regular occurrence f the machine does not reset or continues to trip consult the Troubleshooting Section of this manual 12 Pilot Arc Discussion 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 are not recommended as this will reduce consumable life Occasionally the pilot arc may sputter or start intermittently This is aggravated when the consumables are worn or the air pressure is too high Keep in mind that the pilot arc is designed to transfer the arc to the workpiece and not for numerous starts without cutting 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 If the nozzle is touched to the work while cutting the output current will be reduced to minimum until the nozzle is rem
57. udes SCR PC Board L8321 G2220 1 Contactor Self Tapping Screw M12161 68 8025 65 1 2 4 5 6 7 Contactor Self Tapping Screw M12161 33 8025 65 Auxiliary Transformer 513000 76 ID Sticker CR1 14798 1 ID Sticker CR2 14798 2 High Freq Module Asbly High Freq Firing PC Board Asbly Thread Forming Screw Insulation Capacitor L8452 2 L8430 2 9225 8 520693 513490 142 Capacitor Assembly Self Tapping Screw Plain Washer Lockwasher 31 518689 2 58025 70 59262 23 E106A 2 EP NP BPR o eje Hp RRP BIR Faltz Parts List P 207 F L8322 1 6 12 96 6 12 96 Parts List 207 FREQ BOARD ASSEMBLY Description Mounting Board Asbly 519700 Carriage Bolt Hex Nut Brass Hex Nut 11827 23 1 4 20 1 4 20 Sems Screw Hex Nut Brass Wing Nut 10082 8 10 24 9968 4 Carriage Bolt Hex Nut 11827 23 1 4 20 5 Includes Hi Freq Choke Coil 519689 519688 Mounting Bracket Self Tapping Screw M15609 58025 70 Hi Freq Transformer Asbly Carriage Bolt L9319 11827 28 Resistor Insulating Washer 510404 96 T4479 A
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