Page 1
PRO-CUT 60
(Single Phase)
PLASMA CUTTING SYSTEM
OPERATOR’S MANUAL
For use with all code number machines thru 10394
IM399-D
May, 1999
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 READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT.
And, most
importantly, think before you act
and be careful.
R
®
• 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
World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors
RETURN TO MAIN INDEX
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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 purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040,
Miami, Florida 33135 or CSA Standard W117.2.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
CUTTING SPARKS can
cause fire or explosion.
4.a..Remove fire hazards from the plasma cutting 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 gouging near hydraulic lines.
Have a fire extinguisher readily available.
4.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.
4.c. When not cutting or gouging, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard.
4.d. Do not cut or gouge 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).
4.e. Vent hollow castings or containers before heating, cutting or
gouging. They may explode.
4.f. Do nor fuel engine driven equipment near area where plasma
cutting or gouging.
ARC RAYS can burn.
2.a. Use safety glasses and a shield with the proper filter and cover plates to protect your eyes
from sparks and the rays of the arc when performing or observing plasma arc cutting or
gouging. Glasses,headshield and filter lens
should conform to ANSI Z87. I standards.
2.b. Use suitable clothing including gloves made from durable
flame-resistant material to protect your skin and that of your
helpers from the arc rays.
2.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.
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.
1.b. 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.
1.c. Insulate yourself from work and ground using dry insulation.
When cutting or gouging in damp locations, on metal framework such as floors, gratings or scaffolds and when in positions such as sitting or lying, make certain the insulation is
large enough to cover your full area of physical contact with
work and ground.
1.d. Always be sure the work cable makes a good electrical connection with the metal being cut or gouged. The connection
should be as close as possible to the area being cut or
gouged.
1.e. Ground the work or metal to be cut or gouged to a good electrical (earth) ground.
1.f. Maintain the plasma torch, cable and work clamp in good,
safe operating condition. Replace damaged insulation.
1.g. Never dip the torch in water for cooling or plasma cut or
gouge in or under water.
1.h. 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
burning the operator, others or even piercing safety clothing.
1.j. Also see Items 4c and 6.
WARNING
PLASMA CUTTING or GOUGING can be hazardous.
FUMES AND GASES
can be dangerous.
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 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.b. 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.
3.c. 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.
3.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.
Apr. ‘93
Page 3
– 3 –
FOR ELECTRICALLY
powered equipment.
6.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
6.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s recommendations.
6.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
CYLINDER may explode
if damaged.
5.a. Use only compressed gas cylinders containing 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 maintained in good condition.
5.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
5.c. 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 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.
Apr. ‘93
ELECTRIC AND MA GNETIC FIELDS
may be dangerous
8.a. Electric current flowing through any conductor causes localized Electric and
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 operators 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 the torch cable is on your right side,
the work cable should also be on your right side.
8.d.4. Connect the work cable to the workpiece as close as
possible to the area being cut or gouged.
8.d.5. Do not work next to cutting power source.
4.g. Sparks and spatter are thrown from the 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.
4.h. Connect the work cable to the work as close to the cutting or
gouging area as practical. Work cables connected to the building framework or other locations away from the cutting or
gouging area increase the possibility of the current passing
through lifting chains, crane cables or other alternate circuits.
This can create fire hazards or overheat lifting chains or
cables until they fail.
PLASMA ARC can injure.
7.a. Keep your body away from nozzle and
plasma arc.
7.b. Operate the pilot arc with caution. The pilot arc is capable of
burning the operator, others or even piercing safety clothing.
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PRÉCAUTIONS DE SÛRETÉ
Pour
votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suivantes:
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 toujours
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.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher 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.
c. Maintenir le porte-électrode, la pince de masse, le câble de
soudage et la machine à souder en bon et sûr état defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
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.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie du
corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:
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 rayonnement de l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pantalons 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 tout risque d’incendie dû aux étincelles.
7. Quand on ne soud
e pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible de
la zone de travail qu’il est pratique de le faire. Si on place la
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 autres circuits. Cela peut provoquer des
risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
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 fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations 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 fortement toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté, voir
le code “Code for safety in welding and cutting” CSA Standard
W 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, I’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.
4. Garder tous les couvercles et dispositifs de sûreté à leur place.
Mar. ‘93
Page 5
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TABLE OF CONTENTS
Page
Safety Precautions.............................................................................................................2-4
Introductory Information.......................................................................................................6
Specifications.......................................................................................................................7
Product Description..............................................................................................................8
Preheat Temperature for Plasma Cutting............................................................................8
User Responsibility..............................................................................................................8
Installation.........................................................................................................................9-11
Safety Precautions ........................................................................................................9
Location.........................................................................................................................9
High Frequency Interference Protection........................................................................9
Electrical Input Connection...........................................................................................10
Air Input Connections...................................................................................................11
Output Connections......................................................................................................11
Torch Connection...................................................................................................11
Work Cable and Clamp Installation........................................................................11
Operating Instructions......................................................................................................11-14
Sequence of events......................................................................................................11
Pilot Arc Discussion......................................................................................................12
Procedure Recommendations......................................................................................12
General ..................................................................................................................12
Thin Gauge Sheet Metal........................................................................................12
Expanded Metal.....................................................................................................13
Thick Sections of Metal..........................................................................................13
Gouging .................................................................................................................13
In All Cases............................................................................................................14
Suggestions for Extra Utility from the PRO-CUT System.............................................14
Maintenance Procedures....................................................................................................15
Routine Maintenance....................................................................................................15
Troubleshooting Procedures......................................................................................15-21
Troubleshooting Guide........................................................................................15-18
PRO-CUT 60 Status Lights Operating Modes.....................................................19-20
Procedure for Replacing P.C. Boards....................................................................21
Wiring Diagram PRO-CUT 60.............................................................................................22
Input Supply Connection Diagrams ...................................................................................23
Cutting Torch Connection Diagram.....................................................................................24
Parts Lists......................................................................................................................Appendix
May96
Page 6
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Thank You
for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!
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.
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
CAUTION
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Model Name & Number _____________________________________
Code & Serial Number _____________________________________
Date of Purchase _____________________________________
Whenever you request replacement parts for or information on this equipment always supply the information
you have recorded above.
Page 7
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SPECIFICATIONS
Type 208/230/460/1/60 K1362-1 Handheld Torch with 25 ft. (7.6m) Cable
K1362-2 Handheld Torch with 50 ft. (15.2m) Cable
230/460/1/60 K1361-1 Handheld Torch with 25 ft. (7.6m) Cable
K1361-2 Handheld Torch with 50 ft. (15.2m) Cable
460/575/1/60 K1362-3 Handheld Torch with 25 ft. (7.6m) Cable
K1362-4 Handheld Torch with 50 ft. (15.2m) Cable
K1362-5 Robotic Torch with 50 ft. (15.2m) Cable
K1362-6 Machine Torch with 50 ft. (15.2m) Cable
K1362-7 Robotic Torch with 50 ft. (15.2m) Cable
K1362-8 Machine Torch with 50 ft. (15.2m) Cable
K871-1 [25Ft.(7.6m)Cable] & K871-2 [50Ft.(15.2m)Cable]
Magnum PCT 60 Air Cooled Torch
Input Frequency 60 Hz
Output Rating 60 Amps, 115 volts, 60% Duty Cycle
60 Amps, 115 volts, Maximum Output
45 Amps, 115 volts, 100% Duty Cycle
Pilot Current 22.5 amps
Pilot Duty Cycle 25% (20 seconds out of 80 seconds)
Current Range 25-60 Amps
Maximum OCV 282 Volts
Normal OCV 250 Volts
Input Power
Standard Voltages 208/230/460/1/60 K1362-1, -2, -5, -6
Current 50/45/23 Amps
Other Voltages 230/460/1/60 460/575/1/60
K1361-1, -2 K1362-3, -4, -7, -8
Current 45/23 Amps 23/18 Amps
Idle Current 4.5 amps @ 230V Maximum
Idle Power 0.7 kW Maximum
Power Factor @ Rated Load 0.65
Net Weight
w/25 ft. (7.6 m) Cable 322 lbs/146 kg
w/50 ft. (15.2 m) Cable 329 lbs/149 kgDimensions, H x W x D
Dimensions, H x W x D 34” x 19” x 22” (864mm x 483mm x 559mm)
(includes lift bail and undercarriage)
Page 8
PRODUCT DESCRIPTION
The PRO-CUT®60 is a constant current, single range,
continuous control plasma cutting system. 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 60 comes standard with air regulator,
coarse air filter, oil coalescing filter, and pressure
gauge. The Pro-Cut 60 comes ready to use with the
torch attached. Machines equipped with handheld
torches are available with either 25 ft. (7.6m) or 50 ft.
(15.2m) torch cable. The undercarriage is standard
and is shipped assembled except for the handle. The
machine is capable of cutting with nitrogen or air.
Nitrogen is used to cut aluminum and other nonferrous metals.
The PRO-CUT is controlled by a microprocessorbased system. The machine performs rudimentary
self troubleshooting when powered up, which aids in
field servicing.
– 8 –
PREHEAT TEMPERATURE FOR
PLASMA CUTTING
Preheat temperature control is recommended for optimum mechanical properties, crack resistance and
hardness control. This is particularly important on
high alloy steels and heat treated aluminum. Job conditions, prevailing codes, alloy level, and other considerations may also require preheat temperature control. The following minimum preheat temperature is
recommended as a starting point. 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 preheat temperature may be required. The recommended minimum preheat temperature for plate thickness up to 1/2
inch (12.7m) is 70 (°F) (21.1°C).
USER RESPONSIBILITY
Because design, fabrication, erection and cutting variables affect the results obtained in applying this type
of information, 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 than
those expected. Some adjustments to procedures
may be necessary to compensate for unique individual conditions. Test all procedures duplicating actual
field conditions.
Page 9
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 Operator’s 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
connectiong power cord to input power.
TURN THE INPUT POWER OFF USING THE
DISCONNECT SWITCH AT THE FUSE BOX
BEFORE ATTEMPTING TO CONNECT THE
INPUT POWER LINES.
• Only qualified personnel should perform this installation.
• Turn the power switch on the PRO-CUT “off” before
connecting or disconnecting output cables.
• 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 precautions can result in excessive operating temperatures
and nuisance shutdown of the machine. Before planning the installation, read the section entitled “High
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 70 and 120 psi (482 and
827 kPa). The flow rate is approximately 4.7 cfm (133
l/min.). Failure to observe these precautions could
result in excessive operating temperatures or damage
to the torch.
HIGH FREQUENCY INTERFERENCE
PROTECTION
Since the spark gap oscillator in the high frequency
generator in the machine is similar to a radio transmitter, improper machine installation can result in radio
and TV interference or problems with nearby electronic equipment.
Radiated interference can develop in the following
four ways:
(1) Direct interference radiated from the machine.
(2) Direct interference radiated from the cutting
leads.
(3) Direct interference radiated from feedback into
the power lines.
(4) Interference from reradiation of “pickup” by
ungrounded metallic objects.
Keeping these contributing factors in mind, installing
equipment per the following instructions should minimize 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 ft. (15.2 m). Tape the
leads together when practical.
(3) 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 CAUTION under “Input Connection”, section. The work terminal ground does not ground
the machine frame.
(6) When the machine is enclosed in a metal build-
ing, several good earth driven electrical grounds
around the periphery of the building
are recommended.
Failure to observe these recommended installation
procedures may cause radio or TV interference problems and result in unsatisfactory cutting or gouging
performance resulting from lost high frequency power.
– 9 –
WARNING
Page 10
RECOMMENDED WIRE SIZE FOR PRO-CUT INPUT CONNECTIONS
Based on U.S. National Electrical Code Ambient Temperature 30˚C or Less
Wire Size
(Copper, 75˚C)
Rated Input
Voltage
Less than 230
230
460
Greater than 460
2 Input Wires
#8 (8.4mm2)
#8 (8.4mm2)
#10 (5.3mm2)
#10 (5.3mm
2
)
1 Grounding Wire
#10 (5.3mm2)
#10 (5.3mm2)
#10 (5.3mm2)
#10 (5.3mm
2
)
Fuse
Size
50Amp
50Amp
25Amp
25Amp
INPUT CONNECTIONS
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
machine nameplate. Also be sure the planned installation will meet the any National Electrical Code and
local code requirements. This machine may be operated from a single phase line or from one phase of a
two or three phase line.
Models that have multiple input voltages specified on
the nameplate (e.g. 208/230/460) are shipped connected for the highest 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.
Machine supply line entry provision is next to the
removable panel.
– 10 –
Have a qualified electrician connect the input leads to
L1 and L2 of the terminal block in accordance with
any National Electrical Code, all local codes and the
connection diagram located on the inside of the cover.
Use ferrules provided (S19117-1) for #10 wire. No
ferrule is required for #8 wire. Tighten screws to 16
in/lbs. (1.8 N.M.). See below.
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 specified on the
machine nameplate.
------------------------------------------------------------
WARNING
ELECTRIC SHOCK can kill.
• Make certain that the input power
is electrically disconnected before
removing the screws that hold the
removable rear panel in place.
------------------------------------------------------------
WARNING
Strip Required for #10 (5.3mm2) Wire
Place Ferrule (S19117-1) Over Wire as Shown
Before Insertion into Machine Terminal Block.
For #10 (5.3mm2) AWG Wire Only
.50"
(12.7mm)
Page 11
The frame of the machine must be grounded. A
ground terminal marked with the symbol located at
the left side of the input box is provided for this purpose. 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 multiple voltage input machines, be
sure the
reconnect panel is connected per the following
instructions for the voltage being supplied to the
machine. See Figure 1 in the back of this manual.
• Failure to follow these instructions can cause immediate failure of machine components.
------------------------------------------------------------------------
The PRO-CUT is shipped connected for the highest
nameplate input voltage. To change this connector
for a different input voltage, reconnect the power
straps to their respective terminals corresponding to
the input voltage used.
Fuse the input circuit with the recommended super lag
fuses. Choose an input and grounding wire size
according to local codes or use the Input Connection
table. “Delay type”
(1)
circuit breakers 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.
(1)
Also called “inverse time” or “thermal/magnetic” circuit breakers; circuit
breakers which have a delay in tripping action that decreases as the magnitude of the current increases.
AIR INPUT CONNECTIONS
A source of clean compressed air or nitrogen must be
supplied to the PRO-CUT. The supply pressure must
be between 70 and 120 psi (482 and 827 kPa). The
flow rate is approximately 4.7 cfm (133 l/min). 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
120 psi (827 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 machine.
OUTPUT CONNECTIONS
Torch Connection
The PRO-CUT comes factory equipped with a cutting
torch.
Pictures of the torch along with 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 as given in Figure 2 in the back of this
manual.
Work Cable and Clamp Installation
Attach the work clamp to the work cable (which
extends from the front of the machine) as shown.
Tighten nut and bolt securely.
OPERA TINGINSTRUCTIONS
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.
– 11 –
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.
----------------------------------------------------------------------------
WARNING
CAUTION
CYLINDER may explode if damaged
• Keep cylinder upright and chained to a
fixed support.
• Keep 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 120 psig (827 kPa).
------------------------------------------------------------------------
WARNING
Work cable
Work clamp
Page 12
-The fan should start.
-If 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 for 60 psi (413 kPa),
minimum while air is flowing.
E. Set the Purge/Run switch to Run.
-The air will continue to run for 20 seconds of
postflow. If the trigger is activated within this
time period, the pilot arc will immediately start.
F. When ready to cut, place the work lead on the
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 2.5 seconds and shut off
unless it is brought in contact with the work and
the arc is transferred.
-When the arc is transferred, cutting begins.
Finish the cut to be made and release the trigger.
G. When the trigger is released, the arc will stop.
-The air will continue to run for 20 seconds of
postflow. If the trigger is activated within this
time period, the pilot arc will immediately restart.
H.
If the “Safety” LED lights at any time, check the following:
• Check the assembly of the torch consumables.
If they are not properly in place then the
machine will not start.
• After the problem is found, reset the machine by
pressing the “Safety Reset” button. (It is
possible for electrical noise to trip the safety circuit on rare occasions. This should not be a
regular occurrence.)
• If the machine does not reset or continues to
trip, consult the Troubleshooting Section.
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, is not recommended as these starts
will generally 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. Always 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.
General
• Follow safety precautions as printed inside the
operating manual and on the machine.
• Use the drag cup when hand cutting at medium
or high output.
• Use the proper cutting or gouging procedures
referred to in procedures guideline.
• Use the shield cup with mechanized torches or
when hand cutting at low output.
Thin Gauge Sheet Metal:
Output set below mid-range.
• The torch should be dragged on the metal surface, touching the nozzle lightly to the surface
after piercing a hole. Current control should be
set in the yellow range only.
• The S24114 Drag Cup should not be used at
very low outputs. It may cause erratic arc
action.
– 12 –
ELECTRIC SHOCK CAN KILL.
• Turn off machine at the disconnect
switch on the front of the machine
before tightening, cleaning or replacing
consumables.
----------------------------------------------------------------------------
WARNING
Page 13
• The .035” (0.8mm) nozzle may be used for a
fine cut. Larger nozzles will work and provide
longer life at the expense of a larger cut.
• Do not allow the torch cable or body to contact
hot surface.
• The best quality cut is obtained by reducing the
current to a level that is adequate for the maximum travel speed.
• Aluminum, copper and other nonferrous metals
typically require more current than the same
thickness of steel. Treat these as a thicker section of steel if good results are not obtained.
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 discontinuous 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.
• If the trigger is continuously pressed and
released to obtain the bright pilot arc for long
periods of time, the machine will go into pilot arc
duty cycle limit. This is a 20 seconds out of 80
seconds pilot duty cycle. The pilot arc is disabled in the limit period. Pilot arc duty cycle
limit is indicated by alternately flashing “OUTPUT ON” and “FAULT” 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 the torch cable or body to contact
hot surfaces.
Thick Sections of Metal
Output set above mid-range.
• The best quality and consumable life will be
obtained by holding the torch nozzle off the surface about 1/8” (3.2mm). Output control should
be sent in the red range only. Do not touch the
nozzle to the work or carry a long arc.
• Use the S24114 Drag Cup to protect the torch.
The only reason not to use the Drag Cup when
the output control is in the blue or red regions is
in special tight corners. Always hold at least a
1/8” (3.2mm) standoff in those situations and
use the S18817 shield cup.
• Set the current to the minimum necessary to
make the cut.
•Use the .052” or .042” (1.2 or 1.0mm) nozzle
size. DO NOT use the .035” (0.8mm) nozzle.
• Pierce the plate by slowly lowering the torch
onto it at an angle of about 30° to blow the
dross away from the torch tip and slowly rotate
the torch to a vertical position as the arc
becomes deeper.
• 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.
Gouging:
Output set to maximum.
• Use the gouging nozzle S18497-4
• Use the Shield Cup.
• 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.
• The air pressure may be raised to about 75 psi
(517 kPa) to aid in metal removal.
• 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.
– 13 –
Page 14
In All Cases:
• Do not pause when cutting or gouging the
metal. This is not necessary and causes operational difficulty. Pausing at the edge of the workpiece causes poor consumable life and erratic
operation.
• Always position the torch in 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.
• Do not drag the nozzle above the mid-range
setting.
Always hold a standoff of 1/8” above mid-range.
• Use a Drag Cup where possible but only when
the current is in the blue or red ranges. Drag
the nozzle in the yellow range. The use of the
Drag Cup at low currents (in the yellow range)
may cause problems. Proper use of the Drag
Cup is the best way to get maximum nozzle and
consumable life.
• Use the proper machine setting. Running the
system at maximum output will not produce the
best cutting performance in most situations.
•Use the 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 .035” (0.8mm) nozzle at outputs above the yellow range.
Suggestions for Extra Utility from the
PRO-CUT System:
• In some cases where moderate or thin sections
are being cut, higher air pressure may give better consumable life. At pressures about 80 psi
(551 kPa), the pilot arc may sputter. This may
be an annoyance but it will not damage the
torch or power source. 60 psi (413 kPa) minimum while air is flowing is the recommended
pressure because it is the minimum necessary
to provide proper cooling in all situations. Feel
free to experiment with higher pressures (not to
exceed 120 psi (827 kPa) at the regulator input).
ELECTRIC SHOCK CAN KILL.
• Turn off machine at the disconnect switch on the
front of the machine before tightening, cleaning or
replacing consumables.
------------------------------------------------------------------------
• The PRO-CUT will cut with consumables that are
worn considerably. Many competitive systems
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
breaks off the electrode and bridges the gap between
the 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.
• The electrode has a hafnium insert at the tip which
greatly prolongs the life of the consumable. When
that insert has been consumed, the machine will
automatically turn off output and lock up in “FAULT”.
At this point, replace the electrode and the nozzle; it
is not recommended to continue cutting with an electrode that has consumed all of its hafnium.
• Use of the nozzle with the largest orifice size that produces acceptable cutting results will maximize consumable life. Procedures given are all based on a
.042" (1.0mm) orifice size. Smaller orifice sizes constrict the arc more, raising the energy density and
therefore the temperature. Larger orifice sizes have
an opposite effect. Small orifice nozzles run hotter
and wear faster than large orifice nozzles 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
.035” (0.9mm) orifice size at outputs
above the yel-
low range because it will be quickly destroyed.
• The PRO-CUT 60 is capable of operation with a 50 ft.
(15.2m) 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*. Keep in mind that the condition of the
consumables and air pressure level have a large
impact on pilot arc ignition.
* Neither cutting performance nor machine reliabili-
ty will be lessened by this condition.
– 14 –
WARNING
Page 15
MAINTENANCE PROCEDURE
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 few months, blow the dust off the air
intakes and louvers with compressed air. Also,
blow off the components in the upper compartment 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 second 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 automatically 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.
5. Inspect the cable periodically for any slits or
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.
ELECTRICAL SHOCK CAN KILL.
• Turn off machine at the disconnect switch at the
back of the machine before tightening, cleaning or
replacing consumables.
------------------------------------------------------------------------
Change consumables as required.
TROUBLESHOOTING PROCEDURES
HOW TO USE THIS GUIDE: Carefully read through
each applicable section listed on the following pages.
Remember that most problems are caused by improper setup, such as switch settings, control settings, etc.
If you believe the set up is correct and the trouble still
exists, first check for the obvious: input power, blown
fuses, loose PC board connectors, broken wires and
the like. The sections listed on the following pages
are intended to help you find the less obvious sources
of trouble.
– 15 –
ELECTRIC SHOCK CAN KILL.
BEFORE PERFORMING ANY MAINTENANCE 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.
------------------------------------------------------------------------
WARNING
ELECTRIC SHOCK CAN KILL.
BEFORE PERFORMING ANY MAINTENANCE 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.
------------------------------------------------------------------------
WARNING
WARNING
Page 16
– 16 –
SYMPTOM CHECK
No LED’s light when the power switch is turned on. 1. Check the input power to be sure it is on.
2. Check the power line fuses and machine
connection.
3. Replace line switch.
TORCH WILL NOT LIGHT 1. Low air pressure results in a "no start" condition.
The “MACHINE ON” LED is lit, but there is no "Air Pressure" LED must be lit when air is
response when the trigger is pulled. flowing. Set the machine in purge mode.
The air will turn on. Set the regulator on the
back of the machine for 60 psi minimum. If the
"AIR PRESSURE" LED does not light, raise the
pressure slightly. If the inlet pressure is greater
than 75 psi and the LED is not lit when air is
flowing, there is a leak or the air filters in the
regulator assembly are clogged.
2. Check the "SAFETY" LED. If it is lit, check the
torch consumables and press the "SAFETY
RESET" button.
3. Check the air supply to the machine. If the air
does not flow, the machine will not start.
4. Check the operation of the air solenoid by
switching the machine to "PURGE". The air
should begin to flow and if the pressure is suffi
cient, the "AIR PRESSURE" LED will light.
Return to "RUN" mode. If air does not flow,
check the solenoid by applying 115 VAC to its
input leads. If it is bad, replace the solenoid, or
else replace the control board.
The air begins to flow, the “OUTPUT ON” LED lights 1. Check the torch consumables to be sure they
for a brief period, but no arc is established. are in tight, not dirty or greasy, and in good
shape. Replace the consumables if necessary.
2. Check that CR2 engages.
3. Check for high frequency at the spark gap.
4. Check the high frequency spark gap located
inside the right panel of the machine. It should
be set at .060” (1.52mm)
DISCONNECT ALL
POWER BEFORE ADJUSTING THE HIGH
FREQUENCY CIRCUIT.
5. Blow off the components in the upper compartment with compressed air.
6. Check pilot to 391 for 2 ohm resistance.
7. Check 2 ohm 300 watt resistor.
8. Replace Control PC Board.
Page 17
– 17 –
SYMPTOM CHECK
The arc starts but sputters badly. 1. Check the torch consumables to be sure they
are tight, not dirty or greasy and in good shape.
Replace if necessary.
2. Check air supply for oil or a great deal of water.
If there is oil or a great deal of water, the air
must be filtered or the machine switched to
nitrogen or bottled air.
3. Check the air pressure. The pressure must be
60 psi (413 kPa) minimum while air is flowing.
The "Air Pressure" LED must be lit.
The “THERMAL” LED is lit. The “FAULT” 1. The machine is overheated. Allow it to cool and
LED is blinking. reset. The air intakes of the machine must not
be blocked, or this will become a nuisance.
The “FAULT” LED is lit 1. The Fault circuit monitors the torch to see if it is
shorted as well as internal machine failures.
2. Check the torch consumables to see if they are
melted together or are simply touching each
other. Tighten, clean or replace. See
“Suggestion for Extra Utility from the PRO-CUT
System”.
3. Check the torch cab le to see if it is cut or
punctured. Replace.
4. 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 air flow.
4c) Check the power board. During preflow,
there should be no voltage between work and
electrode and at end of preflow open circuit
voltage should be present. Replace if bad.
5. Replace control PC board.
Alternating “AIR/FAULT” LED lights. 1. Replace control PC board.
The “OUTPUT ON” and “FAULT” LED’s 1. The pilot arc duty cycle has been exceeded.
blink in alternating order. The machine will cool down and the lights will
quit blinking in about 20 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.)
Airflow will not shut off. 1. Check harness 1J7 (C2) and 3J7 (H6).
Page 18
SYMPTOM CHECK
The “SAFETY” LED is lit. 1. The machine will not operate. The machine
senses that the nozzle is not in place, or the
operator could be exposed to dangerous volt
ages if the machine were allowed to operate.
2. Check the nozzle to be sure it is tightly in place.
3. Check the torch consumables to see if they are
melted together or are simply touching each
other. Tighten, clean or replace. See
“Suggestion for Extra Utility from the Pro-Cut
System”.
4. Check the torch cable to see if it is cut or punctured. Replace.
5. Check to see that the torch is hooked to the
machine properly.
6. Push the "SAFETY RESET" button, the LED
should go out. If the LED does not go out, the
thermal sensor in the torch head has actuated.
Note that the thermal sensor exists in the hand
held torches but not the machine or robotic
torches. This sensor prevents the torch from
melting, and should not trip in normal operation.
Wait several minutes until the torch head is cool,
and press the reset button. If the LED does not
go out, check step 2 again before proceeding.
Read the procedures section of this manual for
instruction in proper cutting technique.
7. This circuit rarely trips on power up or because
of noise. If the circuit can be reset, it is Ok to
continue operation.
8. Check the continuity between pins 1 & 3 in the
plastic amp connector on the torch assembly.
This is the 4-pin connector that plugs into the
power source. If the safety circuit is working
properly, there will be continuity when the nozzle
is in place and no continuity when the nozzle is
removed. When the nozzle is in place, there
must be continuity between pins 1 & 3 and the
torch pilot lead. Replace the torch if the continu
ity measurements are not as described, or else
replace the control board.
No OCV when 2 and 4 are closed. 1. 190 VAC across H1 and H2.
2. 250V SCR PC board positive/negative
3. Check across 31/32 for 110 VAC.
4. Replace Control PC board.
– 18 –
Page 19
– 19 –
STATUS
LIGHTS CONDITION SUGGESTIONS
MACHINE ON Should always be on when machine is on. Normal
OUTPUT ON On when there is voltage potential at the 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 FAULT, the pilot arc duty cycle is
exceeded. Wait for machine lights to stop blinking.
AIR PRESSURE On whenever the air pressure is above 60 Normal conditions are purge, preflow,
psi (413 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.
FAULT 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 transistors. or cut.
Light blinking. If cutting tried with air No air connected to machine, air pressure
pressure less than 60 psi (413 kPa) while set too low, or air leak in system.
air is flowing, the machine will wait for air
pressure to become greater than 60 psi
(413 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 1/8” (3.2mm) at high range of machine and
caused by a surge of current the machine nozzle is accidentally touched to work, shorten
was not designed to handle. Release the stickout, or use Drag Cup. Check consumables
trigger and resume cutting or gouging. to see if electrode melted to nozzle.
Light blinking with THERMAL light on. Wait for machine to cool.
PRO-CUT 60 STATUS LIGHTS OPERATING MODES
Page 20
– 20 –
STATUS
LIGHTS CONDITION SUGGESTIONS
SAFETY It is possible that this light could turn on If machine can be reset, it is OK to continue
when power is first applied to machine. operation.
The nozzle is not in place. Securely fasten nozzle in place.
While cutting or gouging if the voltage By pressing reset, the machine will be
between the nozzle and the work is too functional. This occurs most often when the
high, it will put the machine into SAFETY. consumables are wearing out. By removing
the hafnium that builds up on the inside of the
nozzle, it is possible to extend the life of the
consumables.
If the cable is punctured or cut, it can trip By pressing reset, it will clear the SAFETY.
the SAFETY When cutting is tried again, the machine will
either go into FAULT or SAFETY; until that time,
the machine will not indicate a malfunction
condition.
The torch may be overheated. There is Wait for the torch to cool down, and
a thermal sensor in thehand-held torch reset the safety circuit. Read the
heads to protect it during abusive use. procedures section of this manual for
It will not trip in normal use - even if it is instruction in proper cutting technique.
abused heavily.
Page 21
– 21 –
PROCEDURE FOR REPLA CING PC BO ARDS
Before replacing a PC board which is suspected of
being defective, visually inspect the PC board in question for any damage to any of its components and
conductors on the back of the board.
If there is no visible damage to the PC board, install a
new one and see if this remedies the problem. If the
problem is remedied, reinstall the old PC board to see
if the problem still exists. If it does no longer exist
with the old PC board:
1. Check the PC board harness conductor pins for
corrosion, contamination or looseness.
2. Check leads in the plug harness for loose or
intermittent connection.
If PC board is visibly damaged electrically (compo-
nents burned, copper traces opened or damaged),
before possibly subjecting the new PC board to the
same cause of failure, check for possible shorts,
opens or grounds caused by:
1. Frayed or pinched lead insulation.
2. Poor lead termination, such as a poor contact or
a short to adjacent connection or surface.
3. Two or more leads shorted together.
4. Foreign matter or interference behind the PC
boards.
If PC board is visibly damaged mechanically (such
as a part vibrated off or was crushed), inspect for
cause, then remedy before installing a replacement
PC board.
If there is damage to the PC board if replacing PC
board corrects problem, return it to the local Lincoln
Electric Field Service Shop.
ELECTRIC SHOCK CAN KILL.
BEFORE PERFORMING ANY MAINTENANCE 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.
------------------------------------------------------------------------
WARNING
Page 22
– 22 –
CONTROL BOARD
AIR
SOLENOID
J8
CONNECTOR CAVITY NUMBERING SEQUENCE
(VIEWED FROM COMPONENT SIDE OF BOARD)
J12
J2,J10,J21
J5, J9
L10294
REMOTE
LOCAL
OPTIONAL
REMOTE/LOCAL
SWITCH
76D
76B
76C
2A
4A
401
402
POS-D
400D
32D
31D
321D
2D
4D
212D
76D
1
OPTION
BOARD
J23
J19
2
3
4
5
6
7
8
9
1
2
3
4
5
6
2A
4A
403
404
10
11
12
212D
400D
OPTION
JUMPER
J8
HALF OF
J12 OPTION
JUMPER
OPTION
HARNESS
76C
76B
OPTION
JUMPER
J2
J5
OPTION
JUMPER
4D
2D
OPTION
JUMPER
J10
32D
HALF OF OPTION
JUMPER J12
31D
WIRING DIAGRAM - PRO-CUT 60 (SINGLE PHASE)
OPTIONAL
CNC & GMF
INTERFACE
KIT
77D
76
75
NEG
405
POS
77D
9
7
10
76
75
1
2
3
8
J25
403
404
4B
2B
OPTIONAL
TERMINAL
STRIPS
401
402
2B
4B
POS
405
NEG
J4, J7, J20,
J22, J25
J3, J19
J6, J23
321D
324D
324D
(POS-D)
C508
.0047
3000V
C507
.0047
3000V
STATUS BOARD
1
2
3
4
5
6
8
7
J9
211
212
213
214
215
216
218
325
326
SAFETY
RESET
S3
2
L2
S1
TS1
TO PRIMARY
COILS
TO SUPPLY
LINES
TO GROUND
PER NATIONAL
ELECTRICAL CODE
TO GROUND
PER NATIONAL
ELECTRICAL CODE
TO PRIMARY
COILS
S1
TS1
TO SUPPLY
LINES
L2
2
OUTPUT
CONTROL
1
3
2
CW
R1
10K
5
4
1
2
6
3
5
6
3
7
84
9
2
J2
J8
1
12
14
10
11
15
16
13
10
1
2
3
4
567
8
9
319
324
323
322
321
J3
J7
J6
319
PURGE/RUN
SWITCH
(PURGE IS
OPEN)
PRESSURE
SWITCH
PRIMARY
COIL
THERMOSTAT
3
4
6
4
39
1
1
2
11 12
J4
2
4
5
3
6
7
8
1
4
6
J5
335
336
337
2
4
J10
2
CR2
SV1
AIR
SOLENOID
38
36
34
31
CR2
35
31
305
306
307
1
2
43
AMPHENOL
CONNECTION
FROM TORCH
N.A.
389
PILOT
WORK
L1
NEG
BYPASS
BOARD
HI FREQ
ASBLY.
PRI.
PRI.
MAIN TRANSFORMER
GENERAL INFORMATION
ELECTRICAL SYMBOLS PER E1537
RESISTORS = OHM/WATT (1/2 WATT UNLESS
OTHERWISE SPECIFIED)
3
3
75
76 77
304
L501
L502
SPARK
GAP
C1
319
6J12 3J12
4J12 1J12
34
222
221
R5
L503
L504
N.A.
(PILOT LEAD AT THE TORCH).
NOTES
NUMBER 3 IS CONNECTED TO THE NOZZLE
H3
H4
H6
MAIN SEC.
L1
2
1
5
4
1
T1
T2
L1
1
2
1
4
5
T1
T2
TO GROUND
PER NATIONAL
ELECTRICAL CODE
TO PRIMARY
COILS
S1
TS1
TO SUPPLY
LINES
L2
2
3
L1
1
2
1
4
5
T1
T2
6
87
335
32
31
37
C1
R
W
5
10
386
383
384
7
28
332
338 385
31
32
H4
332
338
C2
31
CENTER
BOTTOM
2
6
3
1
7
4
8
PRI.
TOP
5
100W
389
C
300W
40
50W
391
CR2
71
37
2.5K
5W
N.B.
& 208V SINGLE MACHINES ONLY
208 V
C1-32
31-32
H6-C2
H3-H4
115 VAC
C1
32
37
FAN
3
12W
R8
R2
R7
R3
387
1
HI VOLTAGE
TRANSFORMER
TORCH
BULKHEAD
CONNECTOR
389
6, 7, & 8 APPEAR ON TRIPLE VOLTAGE
40
POS
POS
POS
40
71
71
E
40
H1
H2
12VAC
24VAC
24VAC
115
VAC
5
3
1
2
12 VAC
24 VAC
24 VAC
H4
C505
C504
B
TRANSISTOR
MODULE
SEMICONVERTER
MODULES
J21
2
4
3
1
5
6
H3
H2
H1
G2
G1
3
J22
1
3
4
1
2
B
G2
G1
B
+
+
POWER BOARD
J20
NEG
40
A2
A1
K2
K1
40
40
40
40
NEG
40
4
2
C
230 V
460 V
391
2
POS
AUXILIARY COILS
CAPACITORS = MFD/VOLTS
2800
300V
W
C506
.0047
3000V
2
6
3
1
4
208/230/460V460/575V
S1
TO PRIMARY
COILS
TO GROUND
PER NATIONAL
ELECTRICAL CODE
3
2
1
5
4
T1
T2
2
S1
TO PRIMARY
COILS
TO GROUND
PER NATIONAL
ELECTRICAL CODE
3
2
1
5
4
1
T1
T2
460 V
460/575V MAIN TRANSFORMER
208/230/460V OR 230/460V MAIN TRANSFORMER
6
6
575V
72
R
W
C2
H6
L2
TS1
TO SUPPLY
LINES
L1
L2
TS1
TO SUPPLY
LINES
L1
P23
P/N25099
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside
the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number..
July96
Page 23
– 23 –
FIGURE 1- Dual Voltage
FIGURE 1- Triple Voltage
INPUT SUPPLY CONNECTION DIAGRAM
May96May96
FOR DUAL VOLTAGE MACHINE.
NOTE: MACHINES ARE SHIPPED FROM FACTORY CONNECTED
FOR 575 VOLTS
GND.
USE FERRULE
#10 AWG ONLY
575 V., 60HZ.
L2
L1
LINK POSITIONS
LINK
HIGH VOLTAGE
can kill
1. CONNECT L1 & L2 INPUT SUPPLY LINES TO INPUT SIDE
OF THE TERMINAL BLOCK AS SHOWN.
2. CONNECT TERMINAL MARKED 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.
TORQUE TO 16 IN.-LBS.
INPUT SUPPLY CONNECTION DIAGRAM
FOR TRIPLE VOLTAGE MACHINE.
NOTE: MACHINES ARE SHIPPED FROM FACTORY CONNECTED
FOR 440 (OR 460) VOLTS
GND.
10-8-93P
GND.
460 V., 60HZ.
L2
L1
460 V.,60HZ.
{
L2
L1
LINK POSITIONS
M17447
LINK POSITIONS
LINK
LINK
HIGH VOLTAGE
can kill
1. CONNECT L1 & L2 INPUT SUPPLY LINES TO INPUT SIDE
OF THE TERMINAL BLOCK AS SHOWN.
2. CONNECT TERMINAL MARKED 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.
TORQUE TO 16 IN.-LBS.
USE FERRULE
#10 AWG ONLY
7-26-91C
GND.
GND.
230 V.,60HZ.
{
L1
208 V.,60HZ.
{
L1
LINK POSITIONS
L2
LINK POSITIONS
L2
LINK
LINK
M15698
Page 24
– 24 –
FIGURE 2
CUTTING TORCH CONNECTION DIAGRAM
May96
FOR MAGNUM PCT 60
TM
PLASMA TORCH
Do not operate with covers removed
Disconnect input power before servicing
Do not touch electrically live parts
Only qualified persons should install,
use or service this equipment
AMPHENOL
CONNECTOR
STRAIN RELIEF CLAMP
ADAPTER
GAS LINE
PILOT
LEAD
PILOT
BOLT
CABLE BOOT
WORK
WORK LEAD
PRO-CUT 60 POWER SOURCE
7-26-91C
THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A.
1. DISCONNECT INPUT POWER TO THE PRO-CUT
AND TURN MACHINE POWER SWITCH OFF.
2. INSERT TORCH CABLE THROUGH CABLE BOOT.
TURN AND LOCK STRAIN RELIEF CLAMP ONTO
BOLT.
3. CONNECT PILOT LEAD.
4. PLACE GAS LINE FITTING ON ADAPTER AND
SCREW TIGHT.
5. ATTACH AMPHENOL CONNECTOR.
S19941
Page 25
NOTES
Page 26
LLIINNCCOOLLNN EELLEECCTTRRIICC SSEERRVVIICCEE MMAANNUUAALLSS
ORDER FROM: Technical Service Group-Customer Service Dept.
Lincoln Electric Company
22801 St. Clair Ave.
Cleveland, Ohio 44117-1199
All orders must be pre-paid (US Funds Only): Please allow up to 4 weeks for delivery.
Make checks or Money Orders payable to the Lincoln Electric Company
Now Available ...The following Service Manuals
These are comprehensive single sources of information relative to Installation, Operation,
Maintenance, Accessories, Theory of Operation, Replacement Parts, Electrical Diagrams and
Extensive Troubleshooting.
Qty. Titles Machine Codes Manual # Unit Price Total Price
Square Wave Tig 255 (Codes 10022-10134) SVM100-A $45.00
V300I (Codes 9826-10133) SVM101-A $45.00
SP100 (Codes 9284-10050) SVM102-A $45.00
Power Arc 4000 (Codes 10083) SVM103-A $45.00
Power Arc 4000 (Codes 10200-10244) SVM103-B $45.00
ProCut 60 Single Phase (Codes 9819-10118) SVM104-A $45.00
V300 PRO (Codes 9934-10131) SVM105-A $45.00
LN 7 GMA (Codes 9168-9931) SVM106-A $45.00
RANGER 8 (Codes 9972-10110) SVM107-A $45.00
DC600 (Codes 9773-9910) SVM108-A $45.00
POWER WAVE 350/500 (Codes 10104-10155) SVM109-A $65.00
RANGER 9 (Codes 9975-9976) SVM110-A $45.00
SP250 (Codes 9402-10002) SVM111-A $45.00
POWER WAVE 450 (Codes 10105-10195) SVM112-A $65.00
WELDAN POWER 125 (Codes 10158-10160) SVM113-A $45.00
LN25 (Codes 9218-10150) SVM114-A $45.00
SP255 (Codes 10164-10165) SVM115-A $45.00
Idealarc CV-300 (Codes 9456-10181) SVM116-A $45.00
Wire-matic 250 (Codes 9799-10004) SVM117-A $45.00
Square Wave TIG 355 (Codes 9951-9955) SVM118-A $45.00
Wire-matic 255 (Codes 10166,10167) SVM119-A $45.00
Ranger 10-LX (Codes 9975, 9976) SVM120-A $45.00
SHIP MANUALS TO:
Name:
Address:
Phone:
TOT AL
SD-267 3/96
Page 27
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 exercises 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
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 students have graduated. Tuition is low and the training is
“hands on”
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 $700.00
5 weeks of fundamentals
There is a 10% discount on all orders of $50.00 or more for shipment at one time to one location.
Orders of $50 or less before discount or orders outside of North America must be prepaid with charge, check or money order in U.S. Funds Only.
Prices include shipment by 4thClass Book Rate for U.S.A. Mainland Only. Please allow up to 4 weeks for delivery.
UPS Shipping for North America Only. All prepaid orders that request UPS shipment please add:
$5.00 For order value up to $49.99
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$15.00 For order value between $100.00 & $149.00
For North America invoiced orders over $50.00 & credit card orders, if UPS is requested, it will be 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.
METHOD OF PAYMENT: (Sorry, No C.O.D. Orders)
CHECK ONE:
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_______________________________________________
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USE THIS FORM TO ORDER:
Order from: BOOK DIVISION, The Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199
BOOKS OR FREE INFORMATIVE CATALOGS Telephone: 216-383-2211 or, for fastest service, FAX this completed form to: 216-361-5901.
Lincoln Welding School ❐ Titles: Price Code Quantity Cost
(ED-80)
New Lessons in Arc Welding $5.00 L
Seminar Information
❐ Procedure Handbook “Twelfth Edition” $15.00 PH
(ED-45)
How to Read Shop Drawings $4.50 H
Educational Video Information
❐ Incentive Management $5.00 IM
(ED-93)
A New Approach to Industrial Economics $5.00 NA
James F. Lincoln Arc Welding The American Century of John C. Lincoln $5.00 AC
Foundation Book Information
❐ Welding Preheat Calculator $3.00 WC-8
(JFLF-515)
Pipe Welding Charts $4.50 ED-89
SUB TOTAL
Additional Shipping Costs if any
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Page 28
WARNING
AVISO DE
PRECAUCION
ATTENTION
WARNUNG
ATENÇÃO
Spanish
French
German
Portuguese
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
● Do not touch electrically live parts or
electrode with skin or wet clothing.
● Insulate yourself from work and
ground.
● No toque las partes o los electrodos
bajo carga con la piel o ropa mojada.
● Aislese del trabajo y de la tierra.
● Ne laissez ni la peau ni des vête-
ments mouillés entrer en contact
avec des pièces sous tension.
● Isolez-vous du travail et de la terre.
● Berühren Sie keine stromführenden
Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!
● Isolieren Sie sich von den
Elektroden und dem Erdboden!
● Não toque partes elétricas e elec-
trodos com a pele ou roupa molhada.
● Isole-se da peça e terra.
● Keep flammable materials away.
● Mantenga el material combustible
fuera del área de trabajo.
● Gardez à l’écart de tout matériel
inflammable.
● Entfernen Sie brennbarres Material!
● Mantenha inflamáveis bem guarda-
dos.
● Wear eye, ear and body protection.
● Protéjase los ojos, los oídos y el
cuerpo.
● Protégez vos yeux, vos oreilles et
votre corps.
● Tragen Sie Augen-, Ohren- und Kör-
perschutz!
● Use proteção para a vista, ouvido e
corpo.
Page 29
WARNING
AVISO DE
PRECAUCION
ATTENTION
WARNUNG
ATENÇÃO
Spanish
French
German
Portuguese
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
● Keep your head out of fumes.
● Use ventilation or exhaust to
remove fumes from breathing zone.
● Los humos fuera de la zona de res-
piración.
● Mantenga la cabeza fuera de los
humos. Utilice ventilación o
aspiración para gases.
● Gardez la tête à l’écart des fumées.
● Utilisez un ventilateur ou un aspira-
teur pour ôter les fumées des zones
de travail.
● Vermeiden Sie das Einatmen von
Schweibrauch!
● Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
● Mantenha seu rosto da fumaça.
● Use ventilação e exhaustão para
remover fumo da zona respiratória.
● Turn power off before servicing.
● Desconectar el cable de ali-
mentación de poder de la máquina
antes de iniciar cualquier servicio.
● Débranchez le courant avant l’entre-
tien.
● Strom vor Wartungsarbeiten
abschalten! (Netzstrom völlig öffnen; Maschine anhalten!)
● Não opere com as tampas removidas.
● Desligue a corrente antes de fazer
serviço.
● Não toque as partes elétricas nuas.
● Do not operate with panel open or
guards off.
● No operar con panel abierto o
guardas quitadas.
● N’opérez pas avec les panneaux
ouverts ou avec les dispositifs de
protection enlevés.
● Anlage nie ohne Schutzgehäuse
oder Innenschutzverkleidung in
Betrieb setzen!
● Mantenha-se afastado das partes
moventes.
● Não opere com os paineis abertos
ou guardas removidas.
WARRANTY SUPERSEDED
SEE IMWS 1
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