Lincoln IM399-D User Manual

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: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com

World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors

RETURN TO MAIN INDEX

– 2 –

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

– 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.

– 4 –

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

– 5 –

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

– 6 –

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.

– 7 –

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)

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.

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