Lincoln Electric IM10006 User Manual

IM10006

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For use with machines having Code Number:

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, OPE RAT E O R
REPAIR THIS EQUIPME N T
WITHOUT READING THIS
MANUAL AND T HE S A FETY
PRE C A U T I O N S CONT A I N E D
THROUGHOUT . And, m o s t

importantly, think before you act
and be careful.

PLASMA 20

June, 2009

11578

Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com

OPERATOR’S MANUAL

Copyright © Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

i

SAFETY

i

WARNING

PLASMA CUTTING or GOUGING can be hazardous.

PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN
AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information it is strongly recommended that you
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.

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.

to keep fumes and gases away from the breathing zone.

When plasma 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
plasma cutting or gouging on galvanized steel.

3. b. The operation of plasma cutting or gouging fume control
equipment is affected by various factors including proper
use and positioning of the equipment, maintenance of the
equipment and the specific procedure and application
involved. Worker exposure level should be checked upon
installation and periodically thereafter to be certain it is with­in applicable OSHA PEL and ACGIH TLV limits.

3.c. Do not use plasma cutting or gouging equipment 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.d. 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.e. Read and understand the manufacturer’s instructions for this

equipment and follow your employer’s safety practices.

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 ventilation and/or exhaust at the arc

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.

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.

Aug. ‘06

ii

SAFETY

ii

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.

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.

4.I. Read and follow NFPA 51B “ Standard for Prevention During
Welding, Cutting and Other Hot Work”, available from NFPA, 1
Batterymarch Park,PO box 9101, Quincy, Ma 022690-9101.

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.

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.

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.

ELECTRIC AND MAGNETIC
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. Routethetorchandworkcables 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 thetorchcableis on yourrightside,
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.

Jan., 07

NOTES

iv

SAFETY

iv

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.

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 soude 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

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.

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

TThhaannkk YYoouu

vv

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!

The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip­ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln
Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses­sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor­mation or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular purpose,
with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or
correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any
warranty with respect to the sale of our products.

Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in
applying these types of fabrication methods and service requirements.

Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com
for any updated information.

CUSTOMER ASSISTANCE POLICY

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.

Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you

have recorded above. The code number is especially important when identifying the correct replacement parts.

On-Line Product Registration

- Register your machine with Lincoln Electric either via fax or over the Internet.

• For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.

• For On-Line Registration: Go to our

“Product Registration”. Please complete the form and submit your registration.

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:

WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.

CAUTION

This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.

TABLE OF CONTENTS

Page

Installation.......................................................................................................................Section A

Technical Specifications.......................................................................................................A-1

Safety Precautions ...............................................................................................................A-2

Select Proper Location.........................................................................................................A-2

Stacking................................................................................................................................A-2

Tilting....................................................................................................................................A-2

High Frequency Interference Protection...............................................................................A-2

Input Electrical Connections.................................................................................................A-2

Compressed Air or Gas Input Connections..........................................................................A-3

Connections to Ground Cable..............................................................................................A-3

Torch Connections ...............................................................................................................A-3

________________________________________________________________________________

Operation.........................................................................................................................Section B

Safety Precautions ...............................................................................................................B-1

Description ...........................................................................................................................B-1

User Responsibility...............................................................................................................B-2

Design Features and Advantages........................................................................................B-2

Cutting Capability .................................................................................................................B-2

Torch Consumables ............................................................................................................B-2

Limitations ............................................................................................................................B-2

Controls and Settings...........................................................................................................B-2

Cutting Operations ...............................................................................................................B-3

Check Air Quality..................................................................................................................B-3

Cutting with a Hand Torch ............................................................................................B-3, B-4

Pilot Arc Discussion..............................................................................................................B-5

Torch Consumable Parts Selection......................................................................................B-5

________________________________________________________________________

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Maintenance ....................................................................................................Section D

Safety Precautions ................................................................................................D-1

Routine Maintenance.............................................................................................D-1

Periodic Maintenance............................................................................................D-1

Compressed Air Filter............................................................................................D-2

________________________________________________________________________

Troubleshooting..............................................................................................Section E

Safety Precautions.................................................................................................E-1

How to Use Troubleshooting Guide.......................................................................E-1

Troubleshooting Guide ..........................................................................................E-2

________________________________________________________________________

Wiring Diagrams..............................................................................................Section F

Wiring Diagram......................................................................................................F-1

––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––

Parts Lists....................................................................................................P-607Series

________________________________________________________________________

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS - PLASMA 20

INPUT - SINGLE PHASE

Standard Voltage

115/1/50/60Hz (15 Amp Branch)

115/1/50/60Hz (20 Amp Branch with 20 Amp Plug*)

RATED OUTPUT

Duty Cycle

A-1

1Ø Input Current at Rated Output

115 V: 20A @ 50%
115 V: 26A @ 40%

AMPS

50% on 115V (15 Amp Branch)

40% on 115V (20 Amp Branch with 20 Amp Plug*)

OUTPUT

Current

Range

10-20 Amps

Open Circuit

Voltage

310 VDC

REQUIRED AIR FLOW RATE REQUIRED AIR INLET PRESSURE

3.5 cu. ft./min.
(100L/min.)

RECOMMEND INPUT WIRE AND FUSE SIZES

For all plasma cutting applications

Based on U.S. National Electrical Code

Ambient Temperature 30

Output

AC Input

Voltage

at
50/60
Hertz

Plug Size

Maximum

Time-Delay

Circuit Breaker

or Fuse Size

o

C or Less

15 A
20 A

Pilot Current

17 Amps

72.5 to 150 PSI

( 5 Bar TO 10.3 Bar)

Type SJT or Hard Usage

Input Cord

20 A
15 A

115V-1Ø
115V-1Ø

5-20P*

5-15P

20 AMPS

15 Amps

PHYSICAL DIMENSIONS

Height

12 in.

305 mm

Width

6 in.

152 mm

*5-20P plug must comply with the standard for attachment plugs and receptacles, UL498.

PLASMA 20

Depth

16 in.

406 mm

3 Conductor, #14 AWG

Weight

Including

Torch Cable

21 lbs.

9.5 kg.