Lincoln Electric IM588 User Manual

IM588-A

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PCT80, PCT80M & PCT80R Plasma Torches

Safety Depends on You

Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased
by proper installation ... and
thoughtful operation on your part.
DO NOT INSTALL, OPERATE
OR REPAIR THIS EQUIPMENT
WITHOUT READING THIS MAN­UAL AND THE SAFETY PRE­CAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.

PCT80

PCT80M

March, 2001

Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:

PCT80R

OPERATOR’S MANUAL

Copyright © 2001 Lincoln Global Inc.

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

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

i

SAFETY

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents
are known to the State of California to cause can­cer, birth defects, and other reproductive harm.

The Above For Diesel Engines

ARC WELDING 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 W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the
Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.

The Above For Gasoline Engines

i

FOR ENGINE
powered equipment.

1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.

____________________________________________________

1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.

____________________________________________________

1.c. Do not add the fuel near an open flame weld­ing arc or when the engine is running. Stop
the engine and allow it to cool before refuel­ing to prevent spilled fuel from vaporizing on
contact with hot engine parts and igniting. Do
not spill fuel when filling tank. If fuel is spilled,
wipe it up and do not start engine until fumes
have been eliminated.

____________________________________________________

1.d. Keep all equipment safety guards, covers and devices in posi­tion and in good repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other moving parts
when starting, operating or repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safety

guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.

___________________________________________________

1.f. Do not put your hands near the engine fan. Do
not attempt to override the governor or idler
by pushing on the throttle control rods while
the engine is running.

1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.

ELECTRIC AND
MAGNETIC FIELDS
may be dangerous

2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines

2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.

2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.

2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:

2.d.1.

Route the electrode and work cables together - Secure
them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and

work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.

___________________________________________________

1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.

2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.

2.d.5. Do not work next to welding power source.

Mar ‘95

ii

SAFETY

ii

ELECTRIC SHOCK can kill.

3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.

In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.

3.f.

Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.

3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

ARC RAYS can burn.

4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.

4.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.

5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. When

welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.

5.b.

Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating prod­ucts.

5.c. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.

5.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. MSDS forms are available from
your welding distributor or from the manufacturer.

vapors

to

5.e. Also see item 1.b.

Mar ‘95

iii

SAFETY

iii

WELDING SPARKS can
cause fire or explosion.

6.a.

Remove fire hazards from the welding area.

If this is not possible, cover them to prevent

the welding sparks from starting a fire.

materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.

6.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.

6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact can
cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld 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
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society

(see address above).

6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.

Sparks and spatter are thrown from the welding arc. Wear oil

6.f.
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.

6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding 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.

6.h. Also see item 1.c.

Remember that welding sparks and hot

though

they have

Preparation

for Welding and Cutting of

CYLINDER may explode
if damaged.

7.a. Use only compressed gas cylinders
containing the correct shielding 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.

7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjected to

physical damage.

• A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.

7.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.

8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.

8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.

8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.

Mar ‘95

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.

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
zones où l’on 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
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

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 and Sales Spec Number (K-xxx) _____________________________________

Date of Purchase __________________________________

Whenever you request replacement parts for or information on this equipment always supply the information you
have recorded above.

vv

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.

PLASMA TORCH

TABLE OF CONTENTS

Page

SPECIFICATION SUMMARY ........................................................................................................A-1

GENERAL DESCRIPTION............................................................................................................A-2

INSTALLATION..............................................................................................................................A-2

OPERATION..................................................................................................................................B-1

MAINTENANCE ............................................................................................................................C-1

TORCH HEAD AND CABLE REPLACEMENT.......................................................................C-2

TROUBLESHOOTING ..................................................................................................................D-1

PARTS LISTS.......................................................................................P210-K, P210-M and P210-N

vivi

PLASMA TORCH

A-1

SPECIFICATIONS SUMMARY

K1571-1 PCT80 Hand-held Plasma Torch with 25 ft. (7.6m) cable
K1571-2 PCT80 Hand-held Plasma Torch with 50 ft. (15.2m) cable
K1571-3 PCT80M Plasma Machine Torch with 25 ft (7.6m) cable and 24 and 32 pitch gear racks
K1571-4 PCT80M Plasma Machine Torch with 50ft (15.2m) cable and 24 and 32 pitch gear racks
K1571-5 PCT80R Robotic Plasma Torch with 25ft (7.6m) cable
K1571-6 PCT80R Robotic Plasma Torch with 50 ft (15.2m) cable

80 Amps, 100% Duty Cycle

K1571-1 PCT80 Hand-held Plasma Torch with 25 ft. (7.6m) cable, 8.7 lbs (3.95 kg)
K1571-2 PCT80 Hand-held Plasma Torch with 50 ft. (15.2m) cable, 14.2 lbs (6.44 kg)
K1571-3 PCT80M Plasma Machine Torch with 25 ft (7.6m) cable, 15.1lbs (6.85 kg)
K1571-4 PCT80M Plasma Machine Torch with 50ft (15.2m) cable, 15.1 lbs (6.85 kg)
K1571-5 PCT80R Robotic Plasma Torch with 25ft (7.6m) cable, 15.1 lbs (6.85 kg)
K1571-6 PCT80R Robotic Plasma Torch with 50 ft (15.2m) cable, 15.1 lbs (6.85 kg)

INSTALLATION

TYPE

OUTPUT RATING

NET WEIGHT

A-1

Torch

K1571-1
K1571-2
K1571-3
K1571-4
K1571-5
K1571-6

Electrode

S22149

Swirl Ring

Assembly

S22148

TORCH COMPONENTS

O-Rings

Outer:
T13483-36

Swirl:
T13483-23

VORTECH™ Nozzle

For 55A machine:
S22147- 043 (1.09mm) orifice
S22147- 068 (1.73mm) orifice for gouging

F

or 80A machine:
S22147-055 (1.35mm) orifice
S22147-082 (2.08mm) orifice for gouging

Shield

Cup

S22150

Drag

Cup

S22151

PLASMA TORCH

A-2

INSTALLATION

A-2

GENERAL DESCRIPTION

The PCT80, PCT80M and PCT80R plasma torches
have been designed for use with the Pro-Cut 55 and
Pro-Cut 80. All of the torches are single gas, air­cooled, and use a patented HF-less torch start mech­anism. All torches come with a quick connect adapter
for easy installation.

The hand-held torches and mechanized torches are
available with either a 25ft (7.6m) or 50ft (15.2m) cable.

Two styles of mechanized torches are available. The
robotic torch features a 8” (203mm) long, 1.625”
(41.2mm) diameter barrel. The machine torch has a
11” (279mm) long, 1.375” (34.9mm) diameter barrel
with a 32 pitch gear rack. The 32 pitch gear rack can
be easily substituted with a 24 pitch gear rack which is
included with the machine torch.

All of the K1571 plasma torches must have an elec­trode, swirl ring, nozzle and shield cup in order to oper­ate. These parts are used with all amperage machines
except for the nozzles. See the table in SPECIFICA­TIONS SUMMARY for proper nozzle orifice to machine
combination.

INSTALLATION

WARNING

ELECTRIC SHOCK can kill.

• Only qualified personnel should perform
this installation.

• Turn the input power OFF at the discon­nect switch or fuse box before working
on this equipment.

• Do not touch electrically hot parts.

• Do not operate with covers removed.

TOOLS REQUIRED:

None

A. Turn off power to the Pro-Cut at the disconnect

switch or fuse box. Do not proceed until the power
is definitely turned off.

B. To assemble a torch to the Pro-Cut:

1. Facing the front of the Pro-Cut, insert the con­nector with the plastic retaining key in the up
position. Grasp the connector with one hand
while twisting the large lock nut clockwise onto
the threaded bulkhead with the other hand.
Tighten hand tight.

2. For mechanized torches only:

A trigger kit is included with either the machine or
robotic torch. This kit allows for triggering the
power source.

An optional Interface kit can be ordered which
adds Arc Transfer and Voltage Feedback.

C. To remove a torch from the Pro-Cut:

1. Facing the front of the Pro-Cut, grasp the con­nector with one hand while twisting the large
lock nut at the bulkhead counter clockwise with
the other hand. Once the nut is loose, pull the
connector straight back away from the bulk­head. Install per part “B” above.

PLASMA TORCH

A-3

FIGURE A.1

D. Assemble an electrode, nozzle, shield cup and drag

cup on the torch as shown in the Figure A.1. First
insert the electrode with the hafnium insert facing
out. Then, place the nozzle over the electrode and
allow it to seat against the swirl ring. Place the
shield cup over the nozzle and tighten firmly by
hand. Slide the drag cup onto the shield cup for
drag cutting.

INSTALLATION

A-3

AL

WAYS USE GENUINE LINCOLN
ELECTRIC ELECTRODES AND
VORTECH™ NOZZLES

• Only Genuine Lincoln Electric consumables yield the

best cutting performance for the PRO-CUT 55 and
PRO-CUT 80.

• The patented VORTECH™ nozzle provides an extra

“kick” of swirl as the arc exits the nozzle which
improves cutting performance. No other nozzle has

this capability or can match its performance.

E. Restore power to the Pro-Cut.

PLASMA TORCH

B-1

OPERATION

OPERATION

B-1

WARNING

When plasma cutting, it is necessary to wear
proper eye, head and body protection.

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
carbon alloy steels and heat treated aluminum. Job
conditions, prevailing codes, alloy level, and other con­siderations may also require preheat temperature con­trol. The following minimum preheat temperature is
recommended as a starting point. Higher tempera­tures may be used as required by the job conditions
and/or prevailing codes. If cracking or excessive hard­ness occurs on the cut face, higher preheat tempera­ture may be required. The recommended minimum
preheat temperature for plate thickness up to 1/2”
(12.7mm) is 70F (21.1C).

A. Connect the ground lead to the material to be cut.

B. Turn the Pro-Cut “ON” with the power switch on the

front of the machine.

C. Press the Purge switch and hold. Adjust the regu-

lator until the pressure gage reads 70 psi (4.8 Bar.).
Release the Purge switch and the air flow will stop.
The pressure may increase by 5 to 10 PSI after air
flow stops but this is normal.

D. Adjust the output to the desired level. Refer to the

appropriate Lincoln Process and Procedure
Guidelines for recommended output, standoff, noz­zle and cutting technique for your application.

E. Activate the trigger.

• If the air was not already flowing, the Pro-Cut will
allow the air to flow for two seconds before the
pilot arc is started. This is called PREFLOW.

• If the trigger was activated during postflow then
a pilot arc will start instantly.

USER RESPONSIBILITY

Because design, fabrication, erection and cutting vari­ables affect the results obtained in applying this type of
information, the serviceability of a product or structure
is the responsibility of the user. Variation such as plate
chemistry, plate surface condition (oil, scale), plate
thickness, preheat, quench, gas type, gas flow rate and
equipment may produce results different than those
expected. Some adjustments to procedures may be
necessary to compensate for unique individual condi­tions. Test all procedures duplicating actual field con­ditions.

F. Bring the pilot arc close to the material to be cut.

Once the torch is about 1/4” to 1/2” away from the
work piece the arc will automatically transfer to the
work and the Pro-Cut will regulate output to the set­ting on the dial. It is best to minimize the pilot arc
time in order to prolong consumable life. Starting at
the edge of the work piece instead of piercing the
material will also increase consumable life.

G. Release the trigger when the cut is complete. Air

will continue to flow for 10 seconds to cool the
torch. This is called POSTFLOW.

PLASMA TORCH

C-1

MAINTENANCE

WARNING

MAINTENANCE

C-1

ELECTRIC SHOCK CAN KILL

• Only qualified personnel should per­form this installation.

• Turn the input power OFF at the dis­connect switch or fuse box before
working on this equipment.

• Do not touch electrically hot parts.

• Do not operate with covers removed.

Keep the work area clean and free of combustible
materials. Prevent debris and objects from obstructing
air flow around the Pro-Cut.

Check the filter elements every several months to see
if they are clogged (weekly in very dirty environments).
Replace if necessary.

Inspect the cable periodically for any slits or puncture
marks in the cable jacket. Replace if necessary.
Check to make sure that nothing is crushing the cable
and blocking the flow of air through the air tube inside.
Also, check for kinks in the cable and relieve any so as
not to restrict the flow of air to the torch.

Replace the electrode when the pit in the center of the
electrode is deeper than .060" (1.5 mm) or when the
copper portion is severely distorted.

Replace the nozzle when the orifice is no longer round
or when the inside surface is covered with scale.

Green colored arcs indicate the electrode and/or
nozzle are worn and need to be replaced.

PLASMA TORCH

C-2

MAINTENANCE

C-2

REPLACEMENT INSTRUCTIONS
FOR PCT80M or PCT80R CABLE
AND TORCH HEAD ASSEMBLY

WARNING

ELECTRIC SHOCK can kill.

• Turn the input power off to the Pro­Cut using the disconnect switch at
the fuse box before attempting to
replace either the torch head or the
cable assembly.

• Only qualified personnel should install, service
or use this equipment.

• Read instructions thoroughly before beginning.

Tools Required:

Tools Required:
(1) 1/2" open end wrench (1) 5/64" allen wrench
(2) 7/16" open end wrenches

NOTE: The pictures illustrate the machine torch. The
procedure for replacing components on the robotic
torch is similar.

Electrical Connector

Electrode
Lead Connection

5. Using the 7/16" and 1/2" open end wrenches, dis­connect the air connection and remove the entire
torch head assembly.

Air Connection

6. Replace Torch Head or Cable Assembly as follows:

a. For replacing the torch head, obtain a new torch

head and discard the old one if damaged.

b. For replacing the cable assembly, slide the bar-

rel, strain relief nut and strain relief off of the old
cable. Obtain a new cable and discard the old
cable. Slide on the following parts in this order:
Strain relief, strain relief nut, and then barrel.

1. Be sure power is OFF to the machine by using the
disconnect switch at the fuse box. Do not proceed
until power to the machine is disconnected.

2. Unscrew the strain relief and strain relief nut. Slide
strain relief and nut about one foot along the cable.

Strain Relief

Strain Relief Nut

Flat Head
Socket Screw

3. Remove the flat head socket screw using the 5/64"
allen wrench. Grasp shield cup with one hand and
barrel with other. Pull shield cup gently straight for­ward, until air line and solenoid connections are
exposed.

Barrel

Electrode Lead

Air line and
Solenoid connections

PULL

Strain Relief

Strain Relief Nut

Slide parts off in this direction

Barrel

Slide parts on in this direction

7. Assemble the air connections using the 7/16" and
1/2" open wrenches. Then connect the electrical
connectors together.

Air Connection

8. Connect the electrode lead to the screw on the back
of the torch head using the 7/16" nut. Tighten with
the wrench. Tape the electrical connector to the air
line. Tape electrode lead to the air line at the air line
connection.

Barrel

Electrical Connector

O-Rings

4. Using the 7/16" wrench, loosen the nut at the back
of the torch head to remove the electrode lead and
then unplug the electrical connector.

PLASMA TORCH

Tape

Electrode Lead

Air line and
Solenoid connections

C-3

MAINTENANCE

9. Gently slide the barrel up to the torch head.
Continue sliding the barrel carefully over the o-rings
of the torch head, until the hole of the torch head
adapter aligns with the threaded hole of the torch
head. Fasten together using the flat head screw with
5/64" allen wrench, until the head of the screw is
fully seated in the countersunk hole.

Torch Head Adaptor

Flat Head
Socket Screw

10. Thread strain relief nut into barrel and tighten

(Recommended torque - 70-80 in-lbs.). Thread
strain relief onto strain relief nut and tighten
(Recommended torque - 50-60 in-lbs.).

Strain Relief

Strain Relief Nut

C-3

11. Minimum safety check: using an ohm meter verify

that greater than 10 megohms exists between the
barrel and all of the pins on the central adapter
assembly.

12. Restore power to the machine.

PLASMA TORCH

D-1

TROUBLESHOOTING

HOW TO USE TROUBLESHOOTING GUIDE

WARNING

Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and machine
operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please
observe all safety notes and precautions detailed throughout this manual.

__________________________________________________________________________

D-1

This Troubleshooting Guide is provided to help you
locate and repair possible machine malfunctions.
Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM (SYMP­TOMS)”. This column describes possible symptoms
that the machine may exhibit. Find the listing that best
describes the symptom that the machine is exhibiting.

Step 2. POSSIBLE CAUSE.

The second column labeled “POSSIBLE CAUSE” lists
the obvious external possibilities that may contribute to
the machine symptom.

Step 3. RECOMMENDED COURSE OF ACTION

WARNING

ELECTRIC SHOCK CAN KILL

• Only qualified personnel should
perform this troubleshooting.

• Turn the input power OFF at the
disconnect switch or fuse box
before working on this equipment.

• Do not touch electrically hot parts.

• Do not operate with covers removed.

This column provides a course of action for the
Possible Cause, generally it states to contact your local
Lincoln Authorized Field Service Facility.

If you do not understand or are unable to perform the
Recommended Course of Action safely, contact your
local Lincoln Authorized Field Service Facility.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local
Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

PLASMA TORCH

D-2

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

D-2

PROBLEMS

(SYMPTOMS)

The torch does not start when the
trigger is pulled

POSSIBLE CAUSE

FUNCTION PROBLEMS

a. Blown fuse

b. Electrode or nozzle missing

c. Torch misconnected

d. Consumables are worn exces-

sively

e. Torch connections assembled

improperly or shorted

RECOMMENDED

COURSE OF ACTION

a. Make sure all fuses are good

and the Pro-Cut is reconnected
for the proper voltage.

b. Properly assemble an electrode,

swirl ring, nozzle and shield cup
on the torch.

c. Make sure the torch is properly

connected to the front of the
Pro-Cut.

d. Replace electrode and nozzle

and replace shield cup hand
tight.

e. Remove the handles (or barrel)

of the torch and examine all the
connections. Pay attention to
location of electrode lead mount­ing at back of torch head, bro­ken trigger and solenoid leads.

f. Cable damaged

g. Air is not connected or the pres-

sure setting is low.

f. Examine the cable for cuts or

punctures. Make sure there is
continuity from the nozzle at the
torch head to pins 7 & 8 at the
quick connect. Make sure there
is continuity from the electrode at
the torch head to the gas fitting
at the quick connect. Make sure
there is no blockage of airflow in
the cable. Make sure there is
continuity between pins 1 & 9 at
the quick connect while the trig­ger is pulled. Replace any dam­aged cable.

g. Check air supply and connec-

tions.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local
Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

PLASMA TORCH

D-3

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

D-3

PROBLEMS

(SYMPTOMS)

The “Safety” LED is lit

POSSIBLE CAUSE

FUNCTION PROBLEMS

h. Torch head damaged

i. Pro-Cut inoperative

a. Reset button needs to be

pressed.

b. Consumables are missing

c. Consumable are worn.

RECOMMENDED

COURSE OF ACTION

h. Replace torch head and elec-

trode solenoid assembly.

i. Refer to the troubleshooting

guide for the Pro-Cut.

a. After changing consumables the

reset button must be pressed.

b. Make sure an electrode, swirl

ring, nozzle and shield cup are
all properly assembled on the
torch. Always tighten the shield
cup firmly.

c. Replace both electrode and noz-

zle when they appear to be
excessively worn.

d. Torch misconnected

e. Cable damaged

d. Make sure the torch is properly

connected to the front of the
Pro-Cut.

e. Examine the cable for cuts or

punctures. Make sure there is
continuity from the nozzle at the
torch head to pins 7 & 8 at the
quick connect. Make sure there
is continuity from the electrode at
the torch head to the gas fitting at
the quick connect. Make sure
there is no blockage of airflow in
the cable. Make sure there is
continuity between pins 1 & 9 at
the quick connect while the trig­ger is pulled. Replace any dam­aged cable.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local
Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

PLASMA TORCH

D-4

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

D-4

PROBLEMS

(SYMPTOMS)

Only a brief spurt of a Pilot Arc
appears

POSSIBLE CAUSE

FUNCTION PROBLEMS

f. Pro-Cut inoperative.

a. Make sure the air pressure is set

correctly

b. Air flow may be restricted.

c. There may be oil in the air.

d. The Pro-Cut is not working prop-

erly.

RECOMMENDED

COURSE OF ACTION

f. Refer to the troubleshooting

guide for the Pro-Cut.

a. Press the Purge button on the

Pro-Cut and adjust the air pres­sure to 70 psi while the air is
flowing.

b. Check air connection to the Pro-

Cut as well as the torch connec­tion for any blockage of air flow.

c. Check the air filter for oil.

Replace if necessary and elimi­nate the source of oil.

d. Refer to the troubleshooting

guide for the Pro-Cut.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local
Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

PLASMA TORCH

WARNING

Spanish

AVISO DE

PRECAUCION

● Do not touch electrically live parts or

electrode with skin or wet clothing.

● Insulate yourself from work and

ground.

● No toque las partes o los electrodos

bajo carga con la piel o ropa moja­da.

● Aislese del trabajo y de la tierra.

● Keep flammable materials away.

● Mantenga el material combustible

fuera del área de trabajo.

● Wear eye, ear and body protection.

● Protéjase los ojos, los oídos y el

cuerpo.

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

● Ne laissez ni la peau ni des vête-

ments mouillés entrer en contact
avec des pièces sous tension.

● Isolez-vous du travail et de la terre.

● Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!

● Isolieren Sie sich von den

Elektroden und dem Erdboden!

● Não toque partes elétricas e elec-

trodos com a pele ou roupa molha­da.

● Isole-se da peça e terra.

● Gardez à l’écart de tout matériel

inflammable.

● Entfernen Sie brennbarres Material!

● Mantenha inflamáveis bem guarda-

dos.

● Protégez vos yeux, vos oreilles et

votre corps.

● Tragen Sie Augen-, Ohren- und Kör-

perschutz!

● Use proteção para a vista, ouvido e

corpo.

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO
BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER­STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

PLASMA TORCH

● Keep your head out of fumes.

● Use ventilation or exhaust to

remove fumes from breathing zone.

● Turn power off before servicing.

● Do not operate with panel open or

guards off.

WARNING

● Los humos fuera de la zona de res-

piración.

● Mantenga la cabeza fuera de los

humos. Utilice ventilación o
aspiración para gases.

● Gardez la tête à l’écart des fumées.

● Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zones
de travail.

● Vermeiden Sie das Einatmen von

Schweibrauch!

● Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

● Mantenha seu rosto da fumaça.

● Use ventilação e exhaustão para

remover fumo da zona respiratória.

● Desconectar el cable de ali-

mentación de poder de la máquina
antes de iniciar cualquier servicio.

● Débranchez le courant avant l’entre-

tien.

● Strom vor Wartungsarbeiten

abschalten! (Netzstrom völlig öff­nen; Maschine anhalten!)

● Não opere com as tampas removidas.

● Desligue a corrente antes de fazer

serviço.

● Não toque as partes elétricas nuas.

● No operar con panel abierto o

guardas quitadas.

● N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de
protection enlevés.

● Anlage nie ohne Schutzgehäuse

oder Innenschutzverkleidung in
Betrieb setzen!

● Mantenha-se afastado das partes

moventes.

● Não opere com os paineis abertos

ou guardas removidas.

Spanish

AVISO DE

PRECAUCION

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.

PLASMA TORCH

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

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