Lincoln Electric IM594 User Manual
IM594
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PRO-CUT
For use with machines having Code Number:
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thoughtful operation on your part. DO
NOT INSTALL, 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.
10464
TM
20
May, 2000
Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:
OPERATOR’S MANUAL
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
• 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
SAFETY
iii
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.
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.
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.
Mar. ‘93
Thank You
vv
for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!
Please Examine Carton and Equipment For Damage Immediatel
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:
y
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
TABLE OF CONTENTS
Page
Installation.......................................................................................................................Section A
Technical Specifications.......................................................................................................A-1
Safety Precautions ...............................................................................................................A-2
Select Proper Location .........................................................................................................A-2
Stacking................................................................................................................................A-2
Tilting....................................................................................................................................A-2
High Frequency Interference Protection...............................................................................A-2
Input Electrical Connections.................................................................................................A-2
Gas Input Connections.........................................................................................................A-3
Output Connections..............................................................................................................A-3
Torch .............................................................................................................................A-3
Operation.........................................................................................................................Section B
Safety Precautions ...............................................................................................................B-1
Description ...........................................................................................................................B-1
Preheat Temperature for Plasma Cutting.............................................................................B-1
User Responsibility...............................................................................................................B-2
Operational Features and Controls ......................................................................................B-2
Design Features and Advantages ........................................................................................B-2
Cutting Capability .................................................................................................................B-3
Consumable Life ..................................................................................................................B-3
Limitations ............................................................................................................................B-4
Controls and Settings ...........................................................................................................B-4
Pilot Arc Discussion..............................................................................................................B-5
Procedure Recommendations..............................................................................................B-6
General .........................................................................................................................B-6
Thin Gauge Sheet and Material up to 1/4” ....................................................................B-6
Suggestions for Extra Utility from the PRO-CUT System .............................................B-6
vi
Accessories.....................................................................................................Section C
Genuine Lincoln Parts ...........................................................................................C-1
General Options / Accessories..............................................................................C-1
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
Routine Maintenance.............................................................................................D-1
Periodic Maintenance............................................................................................D-1
Troubleshooting..............................................................................................Section E
Safety Precautions.................................................................................................E-1
How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide ..........................................................................................E-2
Wiring Diagrams..............................................................................................Section F
Wiring Diagram ......................................................................................................F-1
Parts Lists........................................................................................................Appendix
PRO-CUT 20 ...........................................................................................P310 Series
Torch................................................................................................................P210-L
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS - PRO-CUT 20 (K1579-1)
INPUT - SINGLE PHASE / 60 HERTZ ONLY
Standard
115/230/1/60Hz 115: 34A@20%
Voltage
1Ø Input Current at Rated Output
230: 18A@20%
RATED OUTPUT
Duty Cycle
AMPS
V
OLTS
A-1
AC Input
Voltage at
60 Hertz
1Ø - 115
1Ø - 230
20% Duty Cycle
20
90
OUTPUT
Current
Range
12-20 Amps
Open Cir
Voltage
400 VDC
cuit
15 Amps @ 50% Duty Cycle
Pilot Current
REQUIRED GAS FLOW RATE REQUIRED GAS INLET PRESSURE
65 PSI @ 240 SCFH
( 4.4 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)
Circuit Breaker
(Delay Type)
20 AMPS
20 AMPS
Type 75
Copper Wire in Conduit AWG (IEC) Sizes
o
C
2 Input Supply Wires
2
#14 (3.2mm
#14 (3.2mm2)
)
1 Ground Wire
#14 (3.2mm
#14 (3.2mm2)
2
)
Height
10.2 in.
260 mm
PHYSICAL DIMENSIONS
Width
6.3 in.
160 mm
Depth
16.1 in.
410 mm
Weight
Including Machine
Torch Cable (Length)
34.8 lbs.
15.8 kg.
A-2
INSTALLATION
A-2
Read entire Installation Section before installing the
PRO-CUT 20.
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.
• Turn the PRO-CUT Power Switch OFF
when connecting power cord to input
power.
___________________________________________
SELECT PROPER LOCATION
Place the Pro-Cut 20 where clean cool air can freely
circulate in and out the side 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.
HIGH FREQUENCY INTERFERENCE
PROTECTION
The Pro-Cut 20 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
(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.
A source of clean, dry air or nitrogen must be supplied
to the Pro-Cut 20. 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 4.0 cfm (113 l/min.). Failure to observe these precautions could result in excessive operating temperatures or damage to the torch.
STACKING
The PRO-CUT 20 cannot be stacked.
TILTING
The PRO-CUT 20 must be placed on a stable, level
surface so it will not topple over.
PRO-CUT 20
INPUT ELECTRICAL
CONNECTIONS
The Pro-Cut 20 is rated for 115VAC or 230VAC inputs
and will automatically reconnect for the supplied voltage. The machine is shipped from the factory for operation on 115VAC 15 amp circuits. Use on 15 amp
branch circuits will limit cutting output as indicated by
the graphics around the output knob. If the output is
set at 20 amps (maximum) the input fuse or circuit
breaker will “blow” in roughly 30 seconds (depending
on fuse type).
To achieve full output current with 115VAC inputs,
replace the 15 amp plug with the supplied 20 amp
plug and connect the unit to a 20 amp branch circuit
with super lag fuses (or equivalent breaker). To install
the supplied 20A plug: Connect the white (neutral)
wire under terminal clamp with silver screw, and black
(hot) wire under terminal clamp with brass screw.
Connect green wire under terminal clamp with green
screw. Tighten terminal wire clamp screws securely.
A-3
INSTALLATION
A-3
WARNING: Failure to wire as instructed may cause
personal injury or damage to equipment. To be
installed or checked by an electrician or qualified person only. Use of normal 20 amp household breakers
may result in over current trips. If breaker trips occur,
reduce the cutting current output until nuisance trips
stop.
The Pro-Cut 20 performs best when connected to
230VAC inputs. To change over to 230VAC operation,
install a 230VAC plug with a current rating greater
than 15 amps.
For use on engine drives, keep in mind the above
input draw restrictions and the following precaution.
The Pro-Cut 20 can be operated on engine driven
generators as long as the 230 volt auxiliary meets the
following conditions:
• The AC waveform peak voltage is below 375 volts*.
• The AC waveform frequency is between 45 and 65
Hz.
• The RMS voltage of the AC waveform is always
greater than 208VAC *.
for 115 VAC input divide these values in half
*
The following Lincoln engine drives meet these conditions when run in the high idle mode:
Ranger 300 engine drives
Commander 400 engine drives
the rear of the machine. To use the air fitting
supplied with the machine (packaged in the
consumable kit), install the fitting in the port at
the rear of the machine.
NOTE: When using nitrogen gas from a cylinder, the
cylinder must have a pressure regulator.
• Maximum psi from a nitrogen gas cylinder to
the PRO-CUT 20 regulator should never
exceed 150 psi.
• Install a hose between the nitrogen gas
cylinder regulator and the PRO-CUT 20
gas inlet.
WARNING
CYLINDER could explode if damaged.
• Keep cylinder upright and chained
to a fixed support.
• Keep cylinder away from areas
where it could be damaged.
• Never lift machine with cylinder
attached.
• Never allow the cutting torch to touch the
cylinder.
Many engine drives do not meet these conditions (eg
LE North America Ranger series, Miller Bobcats, etc).
Operation of the above stated power sources is not
recommended on engine drives not conforming to
these conditions. Such combinations may overvoltage
the Pro-Cut 20 power source.
GAS INPUT CONNECTIONS
Supply the PRO-CUT 20 with clean compressed air or
nitrogen.
• Supply pressure must be between 80 psi
and 150 psi.
• Flow rate should be approximately 4.0
cfm (113 I/min.).
NOTE: Oil in the air supply to the PRO-CUT 20 can
cause severe problems. Use only a clean air
supply.
• Compressed gas can be supplied either
through the air fitting supplied with the
machine or through the 1/4-19 BSPP thread at
• Keep cylinder away from live electrical
parts.
• Maximum inlet pressure 150 psi.
__________________
OUTPUT CONNECTIONS
Torch
The Pro-Cut 20 is sent from the factory with a PCT 20
cutting torch installed. Additional cutting torches can
be ordered from the K1615 series. Hand-held torches
come with 15' or 25’ cables.
Read and understand this entire section before operating the machine.
PRO-CUT 20
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