Lincoln Electric IM590 User Manual

IM590

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PRO-CUT

For use with machines having Code Numbers:

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.

TM

55

10473, 10474, 10475 and 10476

December, 2002

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

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

OPERATOR’S MANUAL

• 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.

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.

to keep fumes and gases away from the breathing zone.

When cutting or gouging on lead or cadmium plated
steel and other metals or coatings which produce highly
toxic fumes keep exposure as low as possible and
below Threshold Limit Values (TLV) using local exhaust
or mechanical ventilation. In confined spaces or in some
circumstances, outdoors, a respirator may be required.
Additional precautions are also required when welding
on galvanized steel.

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

3.c. Gases used for plasma cutting and gouging can displace air
and cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.

3.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your employ­er’s safety practices.

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.

FUMES AND GASES
can be dangerous.

3.a. Plasma cutting or gouging may produce
fumes and gases hazardous to health. Avoid
breathing these fumes and gases.When cutting
or gouging, keep your head out of the fumes.
Use enough ventilation and/or exhaust at the arc

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

Apr. ‘93

ii

SAFETY

ii

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.

Apr. ‘93

iii

NOTES

iii

iv

SAFETY

iv

PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv­antes:

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand on

soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble

de soudage et la machine à souder en bon et sûr état
defonctionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.

2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
du corps.

5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on place
la masse sur la charpente de la construction ou d’autres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de lev­age, câbles de grue, ou autres circuits. Cela peut provoquer
des risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POUR

3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi qu’un verre blanc afin de se protéger les yeux du ray­onnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de
l‘arc.

c. Protéger l’autre personnel travaillant à proximité au

soudage à l’aide d’écrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan­talons sans revers, et chaussures montantes.

LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debranch­er à l’interrupteur à la boite de fusibles.

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

Mar. ‘93

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.

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.

TABLE OF CONTENTS

Page

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

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

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

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

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

Lifting and Moving ................................................................................................................A-2

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

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

Input Electrical Connections.................................................................................................A-3

Input Power Cord Connector Installation..............................................................................A-3

Frame Grounding .................................................................................................................A-3

Gas Input Connections.........................................................................................................A-4

Output Connections..............................................................................................................A-4

Torch Connection..........................................................................................................A-4

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

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

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

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

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

Recommended Processes and Equipment ..........................................................................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

Pilot Arc Discussion..............................................................................................................B-6

Procedure Recommendations..............................................................................................B-6

General .........................................................................................................................B-6

Thin Gauge Sheet Metal ...............................................................................................B-6

Thick Sections of Metal .................................................................................................B-6

Suggestions for Extra Utility from the PRO-CUT System .............................................B-7

vi

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

Genuine Lincoln Parts ...........................................................................................C-1

General Options / Accessories..............................................................................C-1

vii

TABLE OF CONTENTS

Page

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

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

Input Filter Capacitor Discharge Procedure ..........................................................D-1

Routine Maintenance.............................................................................................D-2

Periodic Maintenance............................................................................................D-2

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

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

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

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

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

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

Dimension Print......................................................................................................F-2

Parts List .....................................................................................P309 Series & P210-K

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS - PRO-CUT 55

INPUT - SINGLE or THREE PHASE / 60 HERTZ ONLY

Standard Voltage

1Ø Input Current at Rated Output

A-1

3Ø Input Current at Rated Output

230/460/1 or 3Ø/60 Hz 230V: 55A @ 50%, 40A @ 100%

460V: 30A @ 50%, 23A @ 100%

Idle Current: 0.42 Amps, Idle Power 98 Watts

@ 230V

RATED OUTPUT

Duty Cycle

50% Duty Cycle

100% Duty Cycle

AMPS

55
40

OUTPUT

Current

Range

25-55 Amps

Open Circuit

Voltage

MAX

335 VDC

230V: 28A @ 50%, 21A @ 100%
460V: 17A @ 50%, 15A @ 100%

Pilot Current

18 Amps @ 100% Duty Cycle

AC Input
Voltage at
60 Hertz

1Ø - 230
1Ø - 460

3Ø - 230
3Ø - 460

REQUIRED GAS FLOW RATE REQUIRED GAS INLET PRESSURE

70 PSI @ 360 SCFH

( 4.8 Bar. @ 10160 LHR)

80 to 150 PSI

( 5.4 Bar. TO 10.2 Bar.)

RECOMMEND INPUT WIRE AND FUSE SIZES

For all plasma cutting applications

Based on U.S. National Electrical Code

Ambient Temperature 30oC or Less

Fuse

(Super Lag)

Type 75
Copper Wire in Conduit AWG (IEC) Sizes

o

C

Circuit Breaker

(Delay Type)

Ground Wire

#10 (5.3mm
#10 (5.3mm

#10 (5.3mm2)
#10 (5.3mm2)

2

)

2

)

70 AMPS
40 AMPS

40 AMPS
20 AMPS

Input Supply Wire

2

#8 (8.4mm
#8 (8.4mm

)

2

)

#10 (5.3mm2)
#10 (5.3mm2)

PHYSICAL DIMENSIONS

Weight

Height

12.6 in.

320 mm

idth

W

11.0 in.

280 mm

Depth

26.0 in.

660 mm

Including Machine

Torch Cable (Length)

(25ft/7.6m) (50ft/15.2m)

70 lbs. 85 lbs.

32 kg. 39 kg.

A-2

INSTALLATION

A-2

Read entire Installation Section before installing the
PRO-CUT 55.

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK CAN 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.

• Always connect the PRO-CUT 55 ground­ing terminal (located on the side of the
Case Back Assembly) to a good electrical
earth ground.

• Turn the PRO-CUT Power Switch OFF
when connecting power cord to input
power.

___________________________________________

LIFTING AND MOVING

Either the front or rear handles or both may be used to
lift or move the machine.

NOT use the pull handle on the optional undercar-

DO

riage, if installed, to lift the machine. This handle is not
designed to support the full weight of the machine and
using it to lift the machine could cause personal injury
or damage to the machine.

TILTING

The PRO-CUT 55 must be placed on a stable, level
surface so it will not topple over.

HIGH FREQUENCY INTERFERENCE
PROTECTION

The Pro-Cut 55 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 Pro-Cut
can be minimized

SELECT PROPER LOCATION

Place the Pro-Cut 55 where clean cool air can freely
circulate in through the rear louvers and out through
the front/bottom opening. 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 Pro-Cut 55. Oil in the air is a severe problem
and must be avoided. The supply pressure must be
between 80 and 150 psi. The flow rate is approximate­ly 6.0 cfm (170 l/min.). Failure to observe these pre­cautions could result in excessive operating tempera­tures or damage to the torch.

STACKING

The PRO-CUT 55 cannot be stacked.

(1) Make sure the power supply chassis is connected

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

(2) Keep the work ground clamp isolated from other

work clamps that have high frequency.

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

the clamp as far as possible from other work
clamp connections.

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

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

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

PRO-CUT 55

A-3

INSTALLATION

A-3

INPUT ELECTRICAL
CONNECTIONS

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.

a. The Pro-Cut 55 should be connected only by a

qualified electrician. Installation should be made in
accordance with the U.S. National Electrical Code,
all local codes and the information detailed below.

b. When received directly from the factory, the

machines are internally connected for 230 VAC.
Re-connection will be necessary if a higher input
voltage is used. To reconnect the Pro-Cut to 460
VAC or to connect back to 230 VAC, follow the
directions as outlined below. Follow this procedure
ONLY while the Pro-Cut is disconnected from the
input power and the capacitors have properly dis­charged.

1. Open the access door on the side of the

machine.

INPUT POWER CORD CONNECTOR
INSTALLATION

The Pro-Cut 55 is supplied with one 11' #8 AWG 3
lead input power cord already connected to the
machine. A cord connector provides a strain relief for
the input power cord as it passes through the left rear
access hole. The cord connector is designed for a
cord diameter of .40 - 1.03 in (10.2 - 26.2mm) if it
becomes necessary to install a different input cord.

For three phase connection: Replace input power cord
with a #10 AWG 4 lead cable.

1. Connect leads of input power cord to a fused
power panel. Make sure the green lead is con­nected to the panel and the panel is connected to
a good earth ground.

Install in accordance with all local and national electric
codes.

FRAME GROUNDING

2. For 200 to 230 : Position the large switch
to 200-230.
For 400 to 460 : Position the large switch
to 400-460.

3. Move the "A" lead to the appropriate termi­nal.

The frame of the Pro-Cut 55 must be properly ground­ed. A ground terminal is mounted on the case bottom
directly behind the input power switch for this purpose.
The cable that is sent attached to the machine is con­nected to this ground terminal. See the National
Electric Code for details on proper grounding meth­ods. Install in accordance with all local and national
electrical codes.

PRO-CUT 55