Lincoln Electric IM10026 User Manual

TOMAHAWK ™1000

IM10026

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T

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, OPER-

ATE OR REPAIR THIS EQUIP­MENT WITHOUT READING
THIS MANUAL AND THE
SAFETY PRECAUTIONS CON­TAINED THROUGHOUT. And,

most importantly, think before you
act and be careful.

September, 2012

11581

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

IP23

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.

or gouging, keep your head out of the fumes. Use enough
ventilation and/or exhaust at the arc 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 within applicable
OSHA PEL and ACGIH TLV limits 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. 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 manufacturerʼs instructions for this

equipment and follow your employerʼs 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

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.

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 manufacturerʼs rec­ommendations.

6.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturerʼs 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. 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.

Refer to http://www.lincolnelectric.com/safety for additional safety information.

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 LʼArc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à lʼélectrode 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 sʼisoler 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 lʼeau 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 sʼapplicuent aussi au pistolet de
soudage.

6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque dʼincendie 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 dʼincendie.

8. Sʼassurer que la masse est connectée le plus prés possible
de la zone de travail quʼil est pratique de le faire. Si on place
la masse sur la charpente de la construction ou dʼautres
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 dʼincendie ou dʼechauffement des chaines et des
câbles jusquʼà ce quʼils 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
dʼopérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de lʼarc 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.

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 nʼimporte quelle partie
du corps.

3. Un coup dʼarc peut être plus sévère quʼun coup de soliel,
donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi quʼun verre blanc afin de se protéger les yeux du ray­onnement de lʼarc et des projections quand on soude ou
quand on regarde lʼarc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de
lʻarc.

c. Protéger lʼautre personnel travaillant à proximité au

soudage à lʼaide dʼécrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de lʼarc de
soudage. Se protéger avec des vêtements de protection libres
de lʼhuile, 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 lʼon pique le laitier.

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
lʼélectricité 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, Iʼinstallation et lʼentretien du poste seront
effectués par un électricien qualifié.

3. Avant de faires des travaux à lʼinterieur de poste, la debranch­er à lʼinterrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur
place.

Thank You

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

Your Product”. 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 “Support” and then “Register

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

Gas Input Connections.........................................................................................................A-3

Output Connections..............................................................................................................A-3

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

________________________________________________________________________________

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

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

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

Preheat Temperature for Plasma Cutting.............................................................................B-1

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

Operational Features and Controls ......................................................................................B-2

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

Cutting Capability .................................................................................................................B-3

Consumable Life ..................................................................................................................B-3

Limitations ............................................................................................................................B-4

Controls and Settings ...................................................................................................B-4, B-5

Cutting Process ............................................................................................................B-5, B-6

Gouging Process..................................................................................................................B-6

Torch ....................................................................................................................................B-7

Pilot Arc Discussion..............................................................................................................B-7

Procedure Recommendations..............................................................................................B-7

General .........................................................................................................................B-7

Suggestions for Extra Utility from the TOMAHAWK™ 1000 System ...........................B-8

Torch Part Configurations...........................................................................................B-9, B-10

Machine Interface...............................................................................................................B-11

________________________________________________________________________________

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Accessories...............................................................................................Section C

________________________________________________________________________

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

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

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

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

________________________________________________________________________

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

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

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

Troubleshooting Guide ...........................................................................E-2 Thru E-7

________________________________________________________________________

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

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

________________________________________________________________________

Parts Lists........................................................................................................Appendix

TOMAHAWK™ 1000 .............................................................................P-627 Series

Torch (Hand Held)..........................................................................................P-210-X

Torch (Machine Held).....................................................................................P-210-Y

________________________________________________________________________

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS -TOMAHAWK™ 1000

INPUT - SINGLE PHASE/THREE PHASE/ 50 / 60 HERTZ

Input Voltage +/- 10%

208V/1/50/60

230V/1/50/60

208V/3/50/60

230V/3/50/60

460V/3/50/60

575V/3/50/60

Input Amperes @ Rated Output

38
25
34
23
25
16
21
13

9
6
8
5

50% Duty Cycle

100% Duty Cycle

50% Duty Cycle

100% Duty Cycle

50% Duty Cycle

100% Duty Cycle

50% Duty Cycle

100% Duty Cycle

50% Duty Cycle

100% Duty Cycle

50% Duty Cycle

100% Duty Cycle

RATED OUTPUT AT 40° C

Duty Cycle

100%

50%

CURRENT

40A

60A

OUTPUT

A-1

Circuit Breaker (Delay Type)

40 Amps

30 Amps

15 Amps

VOLTAGE

96VDC

104 VDC

Current

Range

20 - 60 Amps

Open Circuit

Voltage

270 VDC

Pilot Current

20 Amps

REQUIRED GAS FLOW RATE REQUIRED GAS INLET PRESSURE

80.0 PSI @ 275 SCFH

(5.5 Bar. @ 130 ±20% LITERS/MIN.)

87.0 to 109.0 PSI

(6.0 Bar. to 7.5 Bar.)

RECOMMEND INPUT WIRE

For all plasma cutting applications

Based on U.S. National Electrical Code

o

Ambient Temperature 30

Input Cord

Supplied with Machine

C or Less

Type S, SO, ST, STO

or Extra Hard Usage Cord

AWG (IEC) Sizes

1 Ground Wire

2

)

#10 (5.3 mm2)

STO, 600V

Input Supply Wires

#10 (5.3 mm

PHYSICAL DIMENSIONS

Weight

Height

Width

Depth

Including

Torch Cable

15.3 in.

389 mm

9.7 in.

247 mm

TEMPERATURE RANGES

OPERATING TEMPERATURE RANGE

-10°C to +40°C

TOMAHAWK™ 1000

21.65 in.
550 mm

STORAGE TEMPERATURE RANGE

63.9 lbs.
29 kgs

-25°C to +55°C

A-2

Read entire Installation Section before installing the TOMA­HAWK™ 1000 .

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK CAN

INSTALLATION

(1) Make sure the power supply chassis is connected to a

(2) Keep the work clamp isolated from other work clamps that

(3) If the work clamp cannot be isolated, then keep the clamp

(4) When the machine is enclosed in a metal building, several

KILL.

• Only qualified personnel
should install this machine.

• Turn the input power OFF
at the disconnect switch or

fuse box and discharge input capacitors before
working inside the equipment.

• Do not touch electrically hot parts.

• Turn the TOMAHAWK™ 1000 Power Switch OFF
when connecting power cord to input power.

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

SELECT PROPER LOCATION

Place the TOMAHAWK™ 1000 where clean cool air can freely
circulate in and out of the 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.

A source of clean, dry air or nitrogen must be supplied to the
TOMAHAWK™ 1000. Oil in the air is a severe problem and
must be avoided. The supply pressure must be between 80 and
110 psi. The flow rate is approximately 4.0 cfm (113 l/min.).
Failure to observe these precautions could result in excessive
operating temperatures or damage to the torch.

STACKING

The TOMAHAWK™ 1000 cannot be stacked.

TILTING

The TOMAHAWK™ 1000 must be placed on a stable, level sur­face so it will not topple over.

Failure to observe these recommended installation procedures
may cause improper function of the TOMAHAWK™ 1000 or
possibly even damage to the control system or power supply
components.

INPUT ELECTRICAL CONNECTIONS

The TOMAHAWK™ 1000 is rated for 208VAC through 575VAC
input voltages. Before installing the machine, check that input
supply voltage, phase, and frequency are the same as the
machine's voltage, phase, and frequency as specified on the
machine's rating plate.

• The TOMAHAWK™ 1000 should be connected only by a
qualified electrician. Installation should be made in accor­dance with local codes.

INPUT PLUG INSTALLATION

POWER CORD CONNECTION

A power cord is provided and wired into the machine. Follow the
power cord connection instructions.

Single Phase Input

Connect green lead to ground per National Electrical Code.
Connect black and red leads to power.
Wrap white lead with tape to provide 600V insulation.

Three Phase Input

Connect green lead to ground per National Electric Code.
Connect black, red and white leads to power.

A-2

good earth ground. The work terminal ground does NOT
ground the machine frame.

have high frequency.

as far as possible from other work clamp connections.

good earth driven electrical grounds around the periphery
of the building are recommended.

WARNING

Failure to wire as instructed may cause personal injury or

HIGH FREQUENCY INTERFERENCE PRO­TECTION

The TOMAHAWK™ 1000 employs a touch start mechanism for
arc initiation which eliminates high frequency emissions from
the machine as compared with spark gap and solid state type
high frequency generators. Keep in mind, though, that these
machines may be used in an environment where other high fre­quency generating machines are operating. By taking the fol­lowing steps, high frequency interference into the TOMA­HAWK™ 1000 can be minimized

TOMAHAWK™ 1000

•

damage to equipment. To be installed or checked by an
electrician or qualified person only.

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

In all cases, the green or green/yellow grounding wire must be
connected to the grounding pin of the plug, usually identified by
a green screw.

A-3

Attachment plugs must comply with the Standard for
Attachment Plugs and Receptacles, UL498.

The product is considered acceptable for use only when
an attachment plug as specified is properly attached to
the supply cord.

INSTALLATION

ENGINE DRIVEN GENERATOR

For use on engine drives, keep in mind the above
input draw restrictions and the following precaution.

The TOMAHAWK™ 1000 can be operated on engine
driven generators as long as the 230 volt auxiliary
meets the following conditions:

A-3

If these filter ratings are unavailable, anything with a
rating less than, or equal to, 20 micron would be
acceptable to use. In line filter elements will generally
filter the air with little restriction to the airflow until the
element is about 75% contaminated. After this point,
there will be a noticeable pressure drop in the line.
Filter elements should be replaced when a pressure
drop of 8-10 psi is indicated; however, for optimum
performance of the TOMAHAWK™ 1000, the filter
element should be replaced at or before the pressure
drop reaches 8 psi. Be sure to select a filter that will
accommodate the necessary flow rating for the TOM­AHAWK™ 1000 as specified in the Installation section
of this instruction manual under the Gas Input
Connections heading.

• The AC waveform peak voltage is below 400 volts.

• The AC waveform frequency is between 45 and 65
Hz.

The following Lincoln engine drives meet these condi­tions when run in the high idle mode:

Outback 185, Ranger 225, Ranger 250, 250LPG,
305G and 305D engine drives.
Vantage 300, 400, 500 and Air Vantage engine drives.

Operation of the TOMAHAWK™ 1000 is not recom­mended on engine drives not conforming to these
conditions. Such combinations may overvoltage the
TOMAHAWK™ 1000 power source.

GAS INPUT CONNECTIONS

(External Air Supply)

Supply the TOMAHAWK™ 1000 with clean com­pressed air or nitrogen.

• Supply pressure must be between 80 psi
and 110 psi.

• Flow rate should be approximately 275 SCFH
(

130 ±20% LITERS/MIN.

NOTE: Oil in the air supply to the TOMAHAWK™

1000 can cause severe problems. Use only a
clean air supply.

•

Compressed gas can be supplied either through the air
fitting supplied with the machine or through the 1/4-19

BSPP

thread at the rear of the machine. To use the air
fitting supplied with the machine (packaged in the con­sumable kit), apply teflon tape to the fitting threads and
install the fitting in the port at the rear of the machine.

• If compressed air is being used, it is highly recom­mended that an in line filter be installed in the air
supply line ahead of the air connection to the TOMA­HAWK™ 1000.

• A standard nominal 5 micron in line filter is recom­mended; however, for optimum performance, select
a prefilter with a 3 micron absolute rating.

).

NOTE: When using nitrogen gas from a cylinder, the

cylinder must have a pressure regulator.

• Maximum psi from a nitrogen gas cylinder to the
TOMAHAWK™ 1000 regulator should never
exceed 110 psi.

• Install a hose between the nitrogen gas cylinder
regulator and the TOMAHAWK™ 1000 gas inlet.

CYLINDER could explode if damaged.

WARNING

• Keep cylinder upright and
chained to a fixed support.

• Keep cylinder away from areas
where it could be damaged.

• Never lift machine with cylinder
attached.

• Never allow the cutting torch to touch the
cylinder.

• Keep cylinder away from live electrical parts.

• Maximum inlet pressure 110 psi.

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

OUTPUT CONNECTIONS

Torch

The TOMAHAWK™ 1000 is sent from the factory with
a cutting torch and work clamp included. The work
clamp must be securely connected to the work piece.
If the work piece is painted or extremely dirty it may
be necessary to expose the bare metal in order to
make a good electrical connection.

TOMAHAWK™ 1000

B-1

OPERATION

B-1

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK
can kill.

• Do not touch electrically live parts
or electrode with skin or wet
clothing.

• Insulate yourself from work and
ground.

• Always wear dry insulating
gloves.

FUMES AND GASES
can be dangerous.

• Keep your head out of fumes.

• Use ventilation or exhaust to
remove fumes from breathing
zone.

DESCRIPTION

The TOMAHAWK™ 1000 is a constant current, con­tinuous control plasma cutting power source. It pro­vides superior and reliable starting characteristics,
cutting visibility and arc stability. The control system
has a safety mechanism to insure that the nozzle and
electrode are in place before cutting or gouging. This
is extremely important due to the high voltages
involved.

The TOMAHAWK™ 1000 comes standard with an air
regulator and pressure gauge. The machine also
comes with an input power cord and Hand-held torch
with a 25 Ft.(7.6m) cable length. Consumables are
included with each TOMAHAWK™ 1000 purchase so
that cutting can begin right out of the box.
Consumables can also be ordered as individual pack­ages.

The TOMAHAWK™ 1000 initiates the plasma arc with
a simple, yet reliable, touch start mechanism. This
system eliminates many of the failure problems asso­ciated with hi-frequency start systems.

WELDING, CUTTING and
GOUGING SPARKS
can cause fire or explosion

• Keep flammable material away.

• Do not weld, cut or gouge on
containers that have held combustibles.

ARC RAYS
can burn.

• Wear eye, ear and body
protection.

PLASMA ARC
can injure

• Keep your body away from nozzle
and plasma arc.

• Operate the pilot arc with caution. The
pilot arc is capable of burning the
operator, others or even piercing
safety clothing.

PREHEAT TEMPERATURE FOR
PLASMA CUTTING

Preheat temperature control is not necessary in most
applications when plasma arc cutting or gouging.
Preheat temperature control may be necessary on high
carbon alloy steels and heat treated aluminum for crack
resistance and hardness control. 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" (12.7mm) is 70°F (21.1°C).

Duty Cycle

The duty cycle of a plasma machine is the percentage
of time in a 10 minute cycle at which the operator can
operate the machine at rated cutting current.

Observe additional Safety Guidelines detailed in
the beginning of this manual.

TOMAHAWK™ 1000

Example: 60% duty cycle means that is possible cut

for 6 minutes, then the machine stops for 4 minutes.

Refer to the Technical Specification section for more
information about the machine rated duty cycles.