Lincoln Electric IM491 User Manual
PRO-CUT 125
RETURN TO MAIN MENU
PLASMA CUTTING POWER SOURCE
For use with machines having Code Numbers 10384 thru 10388
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thoughtful operation on your part.
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT.
importantly, think before you act
and be careful.
And, most
DO
®
IM491-B
October,1999
R
OPERATOR’S MANUAL
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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.
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.
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 cutting or gouging 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.
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.
Apr. ‘93
– 2 –
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.
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. 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.
– 3 –
Apr. ‘93
PRÉCAUTIONS DE SÛRETÉ
zones où l’on pique le laitier.
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.
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.
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
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.
– 4 –
Mar. ‘93
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
Material Thickness below .75” (19mm) ..................................................................12
Expanded Metal .....................................................................................................13
Material Thickness above .75” (19mm)..................................................................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......................................................................................15-22
Troubleshooting Guide ........................................................................................15-19
PRO-CUT 125 Status Lights Operating Modes...................................................20-21
Procedure for Replacing P.C. Boards....................................................................22
Parts Lists.........................................................................................................................24-33
Input Supply Connection for Triple Voltage Machine..........................................................34
Cutting Torch Connection Diagram.....................................................................................35
Wiring Diagram PRO-CUT 125...........................................................................................36
– 5 –
for selecting a QUALITY product by Lincoln Electric. We want you
Thank You
to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This 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.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
– 6 –
SPECIFICATIONS
Type K1394-* and K1395-*
K880-1[25Ft.(7.6m)Cable] & K880-2 [50Ft.(15.2m)Cable]
Magnum PCT125 Air Cooled Torch
Input Frequency 50 or 60 Hz, 3ø
Output Rating 125 Amps, 148 volts, 60% Duty Cycle
110 Amps, 140 volts, 80% Duty Cycle
100 Amps, 135 volts, 100% Duty Cycle
Pilot Current 26 amps
Pilot Duty Cycle 25% (20 seconds out of 80 seconds)
Current Range 50-125 Amps
Maximum OCV
@10% High Input
Normal OCV 325
Input Power
Standard Voltages 230/460/3/50/60 220/380/440/3/50/60 575/3/60
Current 101/49 @ 60% 102/59/51 @ 60% 40 @ 60%
Idle Current 4.5 amps @ 220V
Idle Power 0.7 kW Maximum
Power Factor @ Rated Load 0.60
Net Weight
w/25 ft. (7.6 m) Cable 480 lbs/218.2 kg
w/50 ft. (15.2 m) Cable 489 lbs/222.3 kg
Dimensions, H x W x D 35.6” x 19” x 22” (905mm x 483mm x 559mm)
(includes lift bail and undercarriage)
357
95/44 @ 80% 87/54/45 @ 80% 33 @ 80%
88/40 @ 100% 81/49/42 @ 100% 32 @ 100%
* Several standard input voltages and options packages are available specified by type number.
– 7 –
PRODUCT DESCRIPTION
The PRO-CUT™ 125 is a constant current, single
range, continuous control plasma cutting system. The
system is one of the most sophisticated on the
market. It provides excellent starting characteristics,
cutting visibility and arc stability. The torch has a
patented safety mechanism which insures that the
consumables are in place before cutting or gouging.
This is extremely important due to the high voltages
involved.
The PRO-CUT 125 comes with an air regulator,
coarse air filter, oil coalescing filter, and pressure
gauge. The machine comes with a 25 ft. torch cable
or a 50 ft. torch cable and a spare parts kit. The
undercarriage is built-in and the unit is shipped
assembled except for the handle. The machine is
capable of cutting with compressed air or nitrogen.
Nitrogen is used to cut aluminum and other nonferrous metals.
The PRO-CUT is controlled by a microprocessorbased system. The machine performs rudimentary
self troubleshooting when started, which aids in field
servicing.
To enhance safety and protection, the 60 second
postflow period is monitored. During the first 12 seconds of postflow, the pilot arc may be initialized with a
single trigger pull. After 12 seconds, the trigger must
be pulled twice to start the pilot arc. The second trigger pull must follow the first within 1 second to initiate
the arc. This prevents accidental starting if the plasma
torch is resting in such a manner that the trigger is
depressed. The postflow time is reset only if the pilot
arc is initialized.
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 recommended minimum preheat temperature is 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 1/4 inch is 70 (°F).
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. Variations such
as plate chemistry, plate surface condition (oil, scale),
plate thickness, preheat, quench, gas type, gas flow
rate and equipment may produce results different than
those expected. Some adjustments to procedures
may be necessary to compensate for unique individual conditions. Test all procedures duplicating actual
field conditions.
Special control circuitry detects when the nozzle is
touched to the workpiece. If the nozzle is touched to
the workpiece, the machine output is instantaneously
reduced which protects the consumables. When the
nozzle is removed form the workpiece, the output will
return to the set level. This feature protects the consumables from accidental damage when cutting at
high currents.
– 8 –
INSTALLATION
SAFETY PRECAUTIONS
● Read the safety precautions at the beginning of
this Operator's Manual before proceeding.
● Only personnel that have read and under-
stood this Operating Manual should install and
operate this equipment.
● Machine must be connected to system ground per
any national, local or other applicable electrical
codes.
● The power switch is to be in the “OFF” position
when connecting power cord to input power.
HIGH FREQUENCY INTERFERENCE
PROTECTION
The PRO-CUT employs a solid state high frequency
torch starting circuit which drastically reduces high frequency emissions from the machine as compared with
spark gap type high frequency generators.
Radiated interference can develop, however, in the
following four ways:
(1) Direct interference radiated from the machine.
WARNING
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”.
(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’ (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
A source of clean, dry compressed air or nitrogen
must be supplied to the PRO-CUT. Oil in the air is a
severe problem and must be avoided. The supply
pressure must be between 80 and 150 psi (551 and
1032 kPa). The flow rate is approximately 8.0 cfm
(225 l/min.). Failure to observe these precautions
could result in excessive operating temperatures or
damage to the torch.
NOTE:
(6) When the machine is enclosed in a metal build-
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 –
The machine frame MUST also be grounded see paragraph under “Input Connection”. The
work terminal ground does not ground the
machine frame.
ing, several good earth driven electrical grounds
around the periphery of the building
are recommended.
ELECTRICAL INPUT CONNECTION
WARNING
ELECTRIC SHOCK can kill.
• Disconnect input power before
proceeding.
• Have a qualified electrician make
the input connections.
• Be sure the voltage, phase and frequency
of the input power is as specified on the
machine nameplate.
------------------------------------------------------------
Before starting the installation, check with the local
power company if there is any question about whether
your power supply is adequate for the voltage,
amperes, phase and frequency specified on the rear
machine nameplate. Also be sure the planned installation will meet the U.S. National Electrical Code and
local code requirements.
Use a three phase
ommended super lag fuses. Choose an input and
grounding wire size according to local codes or use
the table below. “Delay type” circuit breakers (also
called “inverse time” or “thermal/magnetic”; which
have a delay in tripping action that decreases as the
magnitude of the current increases) may be used in
place of fuses. Using fuses or circuit breakers smaller
than recommended may result in “nuisance” tripping
from machine inrush currents even if not cutting or
gouging at high currents.
Models that have multiple input voltages specified on
the rear nameplate (e.g. 230/460) are shipped connected for the higher voltage. If the machine is to be
operated on the lower voltage, it must be reconnected
according to the instructions on the inside of the
removable panel in the center of the rear panel.
Electrical supply lines enter the machine next to the
removable panel.
power supply fused with the rec-
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.
------------------------------------------------------------
Have a qualified electrician connect the input leads to
“U”, “V” and “W” of the reconnect panel in accordance
with the U.S. National Electrical Code, all local codes
and the connection diagram located on the inside of
the cover.
The frame of the machine must be grounded. A
ground terminal marked with the symbol 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 triple voltage input machines, be sure
nect panel is connected per Figure 1 in the back of
this manual, for the voltage being supplied to the
machine.
the recon-
CAUTION
• Failure to follow these instructions can cause immediate failure of machine components.
------------------------------------------------------------------------
The PRO-CUT is shipped connected for the highest
nameplate input voltage. Reconnect the power straps
to their respective terminals corresponding to the input
voltage used.
RECOMMENDED WIRE SIZE FOR PRO-CUT INPUT CONNECTIONS
Based on 1993 U.S. National Electric Code
Wire Size
(Copper, 75°C)
Input
Voltage / Hz.
230/60
460/60
220/50/60
380/50/60
440/50/60
3 Input Wires
#3 (25mm
#8 (10mm2)
#3 (25mm2)
#6 (16mm
#8 (10mm2)
2
2
1 Grounding Wire
)
)
– 10 –
#8 (10mm
#8 (10mm2)
#8 (10mm2)
#8 (10mm
#8 (10mm2)
2
2
Fuse Size
)
)
125Amp
60Amp
125Amp
70Amp
60Amp
AIR INPUT CONNECTIONS
Work Cable and Clamp Installation
WARNING
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 150 psig.
------------------------------------------------------------------------
A source of clean compressed air or nitrogen must be
supplied to the PRO-CUT. The supply pressure must
be between 80 and 150 psi (551 and 1034 kPa). The
flow rate is approximately 8.0 cfm. Oil in the air is a
very severe problem and must be avoided.
Remove the plastic thread protector from the regulator
input port (located on the back of the machine). Use a
suitable gas connection fitting to make the connection
to the available air supply. The input port is a 1/4”
(6.3 mm) NPT thread. Tighten the air fitting to prevent
leakage but do not overtighten. The use of Teflon
tape to seal the connection is recommended.
Attach the work clamp to the work cable per the following:
1. Unplug the machine or turn the power switch to the
“Off” position.
2. Insert the work cable terminal lug with the larger
hole through the strain relief hole in the work clamp
as shown below.
3. Fasten securely with the bolt and nut provided.
Work cable
Work clamp
OPERATING INSTRUCTIONS
Sequence of events:
A. Turn on the line power.
B. Connect the air supply to the machine.
Nitrogen from cylinders may be used with this
machine. The cylinder of nitrogen gas must be
equipped with a pressure regulator. No more than
150 psi (1034 kPa) may be supplied to the regulator
on the machine. Install a hose between the regulator
on the gas cylinder and the gas inlet on the cutter.
OUTPUT CONNECTIONS
WARNING
HIGH FREQUENCY SHOCK CAN
CAUSE INJURY OR FALL.
• Keep the cutting torch and cables in
good condition.
•
Secure yourself in position to avoid a fall.
----------------------------------------------------------------------------
Torch Connection
The PRO-CUT comes factory equipped with a cutting
torch. Cutting torches come with a 25 ft. (7.6 m) or a
50 ft. (15.2 m) cable.
Pictures of the torch and the required replacement
parts are shown in the parts lists in the back of this
manual. The ends of the cable to be connected to the
power source are unique. Follow the applicable
instructions given in Figure 2 in the back of this manual.
C. Turn the power switch on.
-The green “Power On” LED should begin to
glow.
-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 so that the pressure
gauge reads 60 psi (414 kPa).
E. Set the Purge/Run switch to Run.
-The air will continue to run for 60 seconds of
postflow. If the trigger is activated within the first
twelve seconds, the pilot arc will immediately
start. After twelve seconds, a double trigger pull
is required to start the arc. The second trigger
pull must follow the first within one second to
start the pilot arc.
– 11 –
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 1.8 seconds and shut off
unless the plasma is brought in contact with the
work and the arc is transferred.
Pilot Arc Discussion:
The PRO-CUT has a smooth, continuous pilot arc.
The pilot arc is only a means of transferring the arc to
the workpiece for cutting. Repeated pilot arc starts, in
rapid succession, are not recommended, as this will
reduce consumable life. Occasionally, the pilot arc
may sputter or start intermittently. This is aggravated
when the consumables are worn or the air pressure is
too high. Keep in mind that the pilot arc is designed to
transfer the arc to the workpiece and not for numerous
starts without cutting.
Procedure Recommendations
-When the arc is transferred, cutting begins.
When finished cutting, release the trigger.
G. When the trigger is released, the arc will stop.
-The air will continue to run for 60 seconds of
postflow. If the trigger is activated within the
first 12 seconds, the pilot arc will immediately
restart. After twelve seconds, a double trigger
pull is required to start the arc. The second trigger pull must follow the first within one second
to start the pilot arc.
H.
If the “Safety” LED lights at any time, check the following:
WARNING
ELECTRIC SHOCK CAN KILL.
• Turn off machine at the disconnect
switch at the back of the machine before
tightening, cleaning or replacing consumables.
------------------------------------------------------------------------
When properly used, plasma arc cutting or gouging is
a very economical process. Improper use will result in
a very high operating cost.
If the nozzle is touched to the work while cutting, the
output current will be reduced to minimum until the
nozzle is removed from the work.
General
• Follow safety precautions as printed inside the
operating manual and on the machine.
• Either the S19972 standoff guide or S19973
and S19974 contact attachments are recommended for all cutting applications to protect the
torch from dross and improper arcing conditions.
• Use proper cutting or gouging procedures
referred to in procedures guideline.
Material thickness below .75 (19mm):
• Check the assembly of the torch consumables.
If they are not properly in place then machine
will not start.
• Check the conditions of the inside of the nozzle.
If debris has collected, scrape it out with a piece
of sturdy wire or a suitable drill bit. Refer
to“Suggestions for Extra Utility from the PROCUT system”.
• 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 of this
manual.
Output set below mid-range.
• Do not allow the torch cable or body to contact
hot surfaces.
• The best cut quality is obtained by reducing the
current to a level that is adequate for the maximum travel speed.
• Aluminum, copper and other nonferrous metals
typically require more current than the same
thickness of steel.
• For thickness below .75” (19mm) use an
S19961-2 nozzle (1.4mm dia. orifice). The
S19972 standoff guide should be set in the lowest position for maximum standoff.
– 12 –
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