Lincoln Electric IM595 User Manual

IM595-A

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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

80

10573, 10574, 10575, 10576, 10577, 10578
11019, 11020, 11021, 11022, 11023, 11024

May, 2004

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

OPERATOR’S MANUAL

Copyright © 2004 Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

i

SAFETY

i

WARNING

PLASMA CUTTING or GOUGING can be hazardous.

PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN
AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information it is strongly recommended that you pur­chase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040,
Miami, Florida 33135 or CSA Standard W117.2.

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

ELECTRIC SHOCK can
kill.

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

1.b. When the power source is operating voltages in excess of
250 volts are produced. This creates the potential for serious
electrical shock - potentially even fatal.

1.c. Insulate yourself from work and ground using dry insulation.
When cutting or gouging in damp locations, on metal frame­work such as floors, gratings or scaffolds and when in posi­tions such as sitting or lying, make certain the insulation is
large enough to cover your full area of physical contact with
work and ground.

1.d. Always be sure the work cable makes a good electrical con­nection with the metal being cut or gouged. The connection
should be as close as possible to the area being cut or
gouged.

1.e. Ground the work or metal to be cut or gouged to a good elec­trical (earth) ground.

1.f. Maintain the plasma torch, cable and work clamp in good,
safe operating condition. Replace damaged insulation.

1.g. Never dip the torch in water for cooling or plasma cut or
gouge in or under water.

1.h. When working above floor level, protect yourself from a fall
should you get a shock.

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

1.j. Also see Items 4c and 6.

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

NOTES

iv

SAFETY

iv

PRÉCAUTIONS DE SÛRETÉ

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

Sûreté Pour Soudage A 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

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.

Product _________________________________________________________________________________

Model Number ___________________________________________________________________________

Code Number or Date Code_________________________________________________________________

Serial Number____________________________________________________________________________

Date Purchased___________________________________________________________________________

vv

Where Purchased_________________________________________________________________________

Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.

On-Line Product Registration

- Register your machine with Lincoln Electric either via fax or over the Internet.

• For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.

• For On-Line Registration: Go to our

“Product Registration”. Please complete the form and submit your registration.

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:

WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then

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.

vi

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

Power Input Connection for 208/230/460 Volt Machines .....................................................A-3

Power Input Connection for 200/380-415 Volt Machines .....................................................A-3

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

Cord Removal ...............................................................................................................A-3

Cord Installation ............................................................................................................A-3

Frame Grounding .................................................................................................................A-4

Input Voltage Reconnection Procedure................................................................................A-4

Use on Engine Driven Power Supplies ................................................................................A-4

Gas Input Connections.........................................................................................................A-5

Output Connections..............................................................................................................A-5

Torch Connection..........................................................................................................A-5

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

Gas Pressure Settings .........................................................................................................B-4

Preparing to Cut ...................................................................................................................B-4

Safety LED ...........................................................................................................................B-5

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

Machine Interface.................................................................................................................B-7

vi

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

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

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

vii vii

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 thru E-7

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

Wiring Diagrams.......................................................................................F-1 thru F-4

Dimension Print......................................................................................................F-5

Parts List........................................................................................P340, P210-K Series

TABLE OF CONTENTS

Page

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS - PRO-CUT 80

INPUT

THREE PHASE SINGLE PHASE

Standard Input Current

Voltage at Rated Output Model

208/230/460 48/44/25 50/60 Hz
200/380-415 46/27/24 50/60 Hz

460/575 25/20 50/60 Hz

Standard Input Current

Voltage at Rated Output Model

208/230/460 87/81/48 50/60Hz

RATED OUTPUT

Duty Cycle

AMPS

A-1

VOLTS

60% Duty Cycle

100% Duty Cycle

Current

Range

35-85 Amps

REQUIRED GAS FLOW RATE REQUIRED GAS INLET PRESSURE

70 PSI @ 480 SCFH

( 4.8 Bar. @ 13550 LHR)

RECOMMEND INPUT WIRE AND FUSE SIZES

For all plasma cutting applications Based on U.S. National Electrical Code

Ambient Temperature 30oC or Less

RECOMMENDED INPUT WIRE AND FUSE SIZES

THREE PHASE SINGLE PHASE

Type 75°C

Type 75°C Copper

Fuse Copper Ground

(Superlag) Wire in Wire in

Input or Conduit Conduit

Voltage Breaker AWG (IEC) AWG (IEC)

Frequency

(1)

Size Sizes Sizes

80
60

OUTPUT

Open Circuit

Voltage

MAX

335 VDC

Input or Conduit Conduit

Voltage Breaker AWG (IEC) AWG (IEC)

Frequency

140
130

Pilot Current

20 Amps @ 100% Duty Cycle

80 to 120 PSI

( 5.4 Bar. to 8.1 Bar.)

Type 75°C Copper

Fuse Copper Ground

(Superlag) Wire in Wire in

(1)

Size Sizes Sizes

Type 75°C

200/50/60 60 8 (8.4mm2) 8 (8.4mm2)
208/50/60 60 8 (8.4mm2) 8 (8.4mm2)

230/50/60 60 8 (8.4mm2) 8 (8.4mm2)

380-415/50/60 40 10 (6mm2) 10 (6mm2)

460/50/60 40 10 (6mm

575/50/60 30 10 (6mm2) 10 (6mm2)

2

) 10 (6mm2)

PHYSICAL DIMENSIONS

idth

Height

16.5 in.

419 mm

(1) Input voltage must be within ±10% of rated value.

W

13.75 in.
349 mm

208/50/60 100 4 (21.1mm2) 4 (21.1mm2)

230/50/60 100 4 (21.1mm2) 4 (21.1mm2)

460/50/60 60 8 (8.4mm2) 8 (8.4mm2)

Weight

Depth

Including Machine, Torch and

Torch Cable (Length)

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

29.5 in.

749 mm

98 lbs. 113 lbs.

44.5 kg. 51.4 kg.

A-2

INSTALLATION

A-2

Read entire Installation Section before installing the
PRO-CUT 80.

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 80 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 80 must be placed on a stable, level
surface so it will not topple over.

HIGH FREQUENCY INTERFERENCE
PROTECTION

The PRO-CUT 80 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 80 where clean cool air can
freely circulate in through the rear louvers and out
through the side/bottom openings. 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 80. Oil in the air is a severe problem
and must be avoided. The supply pressure must be
between 80 and 120 psi. The flow rate is approximate­ly 8.0 cfm (227 l/min.). Failure to observe these pre­cautions could result in excessive operating tempera­tures or damage to the torch.

STACKING

The PRO-CUT 80 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 80

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.

The Pro-Cut 80 should be connected only by a quali­fied electrician. Installation should be made in accor­dance with all local and national codes (eg: U.S.
National Electrical Code) and the information detailed
below.

THREE PHASE POWER INPUT CONNEC­TION FOR THE PRO-CUT 80

The Pro-Cut 80’s are supplied with one 10 ft. #8 AWG
4-conductor input power cord already connected to
the machine. When received from the factory, the
machine is internally connected for the higher input
voltage. Re-connection will be necessary if a lower
input voltage is used.

CORD REMOVAL:

1. Unplug line cord from the receptacle.

WARNING

NOTE: DO NOT PERFORM THE NEXT STEP
UNTIL THE HIGH VOLTAGES INSIDE THE
MACHINE HAVE BEEN ALLOWED TO DISSIPATE,
APPROXIMATELY TWO MINUTES.

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

2. Remove wraparound by unscrewing the eleven
screws on the case sides and top.

3. Unscrew the four screws that hold the line switch
onto the case front.

4. Pull the line switch out of the case front.

5. Angle the line switch so the nuts on the switch can
be loosened.

6. Remove the cord from the switch.

7. Remove the nut, lock washer, plain washer and
green lead off of the ground screw assembly.

8. Loosen the cable connector on the case back.

9. Pull the line cord out of the machine.

CORD INSTALLATION:

CONVERTING THE PRO-CUT 80 FROM
THREE PHASE TO SINGLE PHASE INPUT

To convert to single phase power, the 4-conductor
input cord may still be used, but the red lead must be
disconnected and insulated.

1. Connect the green lead to ground per U.S. National
Electrical Code.

2. Connect black and white leads to power.

3. Wrap red lead with tape to provide 600V insulation.

WARNING

Machine damage could result if the machine is
improperly configured for the Input Voltage
applied.

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

INPUT POWER CORD CONNECTOR
INSTALLATION

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.

1. Feed the new cord through the cable connector
and into the machine.

2. If the ground screw assembly is loose, tighten the
assembly to the base before installing the new
ground lead. Install the green lead on the ground
screw assembly, replace the plain washer and lock
washer, then tighten nut. Install in accordance with
all local and national electrical codes.

3. Connect the new cord to the switch, observing the
color code on the wiring diagram.

4. Feed the line switch back into case front.

5. Replace the four screws that hold the line switch
onto the case front.

6. Tighten the cable connector on the case back.

7. Replace wraparound and tighten the eleven
screws on the case sides and top.

8. Connect the new input power cord to a fused three
phase power supply. 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.

NOTE: Fusing requirements of the machine input will
change, depending on whether the machine is used
on single phase or three phase. Use the chart in the
TECHNICAL SPECIFICATIONS to change the fuses
to the proper value.

PRO-CUT 80

A-4

INSTALLATION

A-4

FRAME GROUNDING

The frame of the Pro-Cut 80 must be properly ground­ed. A ground terminal marked 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.

INPUT VOLTAGE RECONNECTION
PROCEDURE

When changing input voltages, it is necessary to
change the settings behind the access door on the
side of the machine. Failure to do so may result in

damage to the machine.

To reconnect the Pro-Cut, 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 back of the machine.

2. For 200 to 230 : Position the large switch to 200-230.
For 400 to 460 : Position the large switch to 400-460.
For 550 to 575 : Position the large switch to 550-575.

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

For 380 - 415 VAC Supplies:

The AC wave form peak voltage must be below 840
volts.
The RMS voltage must be 400 VAC +/- 10%.

For 460 VAC Supplies:

The AC wave form peak voltage must be below 840
volts.
The RMS voltage of the AC wave form must be 460
VAC +/- 10%.

Input Power Restrictions

The available output current of the Pro-Cut 80 may be
limited due to the output capacity of the engine driven
power supply. The following are recommended output
current settings when used with various Lincoln
engine driven power supplies.

Engine Drive Auxiliary Power Pro-Cut 80 Output Cut Thickness

RANGER 8 8KW 30 Amps 5/16”
RANGER 9 9KW 40 Amps 3/8”
GX271 8KW 30 Amps 5/16”
RANGER 275 9KW 40 Amps 3/8”
RANGER 250 8.5KW 35 Amps 5/16”
RANGER 300D 12KW 55 Amps 5/8”
RANGER 305G 9.5KW 40 Amps 3/8”
RANGER 305D 9.5KW 40 Amps 3/8”
COMMANDER 300 10KW 45 Amps 1/2”
COMMANDER 400 10K 45 Amps 1/2”
COMMANDER 500 12KW 55 Amps 5/8”
VANTAGE 500 12KW 55 Amps 5/8”

USE ON ENGINE DRIVEN POWER SUPPLIES

The Pro-Cut 80 can be used on engine driven power
supplies. However, the following AC Wave Form
Voltage and Input Power Restrictions do apply.

AC Wave Form Restrictions

The Pro-Cut 80 can be operated on engine driven
generators as long as the engine drive output meets
the following conditions:

The AC wave form frequency is between 45 and 65
Hz.

For 200 - 230 VAC Supplies:

The AC wave form peak voltage must be below 420
volts.
The RMS voltage must be 230VAC +/- 15%.

* The 230 VAC auxiliaries of Lincoln engine drives

meet these conditions when run in the high idle
mode.

PRO-CUT 80