Lincoln Electric IM637-A User Manual

IM637-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.

March, 2005

10571, 10572, 10475, 10476, 10586 and 10587 11011, 11012, 11013, 11014, 11015 and 11016

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

OPERATOR’S MANUAL

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

SAFETY

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

SAFETY

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

SAFETY

PRÉCAUTIONS DE SÛRETÉ

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

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

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

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

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

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

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

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

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

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

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

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

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

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

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

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

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

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

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

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

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

a. Utiliser un bon masque avec un verre filtrant approprié

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

b. Porter des vêtements convenables afin de protéger la

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

c. Protéger l’autre personnel travaillant à proximité au

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

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

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

PRÉCAUTIONS DE SÛRETÉ POUR LES MACHINES À SOUDER À TRANSFORMATEUR ET À REDRESSEUR

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

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

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

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

Mar. ‘93

for selecting a QUALITY product by Lincoln Electric. We want you

Thank You

to take pride in operating this Lincoln Electric Company product

••• as much pride as we have in bringing this product to you!

Please Examine Carton and Equipment For Damage Immediately

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received.

Please record your equipment identification information below for future reference. This information can be found on your machine nameplate.

Product _________________________________________________________________________________

Model Number ___________________________________________________________________________

Code Number or Date Code_________________________________________________________________

Serial Number____________________________________________________________________________

Date Purchased___________________________________________________________________________

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.

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, 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

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

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

Wiring Diagram ........................................................................................F-1 thru F-4

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

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

TABLE OF CONTENTS

Page

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS - PRO-CUT 55

INPUT

THREE PHASE SINGLE PHASE

Standard Input Current

Voltage at Rated Output Model

208/230/460 31/28/17 50/60 Hz

200/380-415 30/17/16 50/60 Hz

460/575 17/14 50/60 Hz

Standard Input Current

Voltage at Rated Output Model

208/230/460 60/55/30 50/60Hz

RATED OUTPUT

Duty Cycle

AMPS

A-1

VOLTS

50% Duty Cycle

100% Duty Cycle

Current

Range

25-60 Amps

REQUIRED GAS FLOW RATE REQUIRED GAS INLET PRESSURE

70 PSI @ 360 SCFH

( 4.8 Bar. @ 10160 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

55 40

OUTPUT

Open Circuit

Voltage

MAX

335 VDC

Input or Conduit Conduit

Voltage Breaker AWG (IEC) AWG (IEC)

Frequency

108 100

Pilot Current

18 Amps @ 100% Duty Cycle

80 to 150 PSI

( 5.4 Bar. TO 10.2 Bar.)

Type 75°C Copper

Fuse Copper Ground

(Superlag) Wire in Wire in

(1)

Size Sizes Sizes

Type 75°C

208/50/60 40 10 (6mm2) 10 (6mm2)

230/50/60 40 10(6mm2) 10 (6mm2)

460/50/60 30 10 (6mm

200/50/60 40 10 (6mm2) 10 (6mm2)

380-415/50/60 30 10 (6mm2) 10 (6mm2)

460/50/60 30 10 (6mm

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

) 10 (6mm2)

PHYSICAL DIMENSIONS

idth

Height

12.6 in.

320 mm

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

11.0 in.

280 mm

208/50/60 80 8 (8.4mm2) 8 (8.4mm2)

230/50/60 80 8 (8.4mm2) 8 (8.4mm2)

460/50/60 40 10 (6mm

) 8 (8.4mm2)

Weight

Depth

Including Machine, Torch and

Torch Cable (Length)

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

26.0 in.

660 mm

70 lbs. 85 lbs.

32 kg. 39 kg.

A-2

SAFETY PRECAUTIONS

INSTALLATION

LIFTING AND MOVING

A-2

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

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.

___________________________________________

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-

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.

The Pro-Cut 55 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.

SINGLE PHASE INPUT CONNECTION FOR 208/230/460 VOLT MACHINES

The 208/230/460 Volt Pro-Cut 55 is supplied with one 11 ft. #8 AWG 3-conductor input power cord (with a molded 230 VAC plug on one end) already connected to the machine. When received from the factory, this machine is internally connected for 230 VAC. Re-connection will be necessary if a higher or lower input voltage is used.

CONVERTING 200/380-415 VOLT & 460/575 VOLT MACHINES 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.

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.

CORD REMOVAL:

1. Unplug line cord from the receptacle.

CONVERTING A 208/230/460 VOLT MACHINE FROM SINGLE PHASE TO THREE PHASE INPUT

To convert to three phase power, the 230 VAC 3-conductor power cord must be removed and replaced with a #10 AWG 4-conductor power cord.

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

2. Connect black, red and white leads to power.

THREE PHASE POWER INPUT CONNECTION FOR 200/380-415 VOLT & 460/575 VOLT MACHINES

The 200/380-415 Volt and 460/575 Volt Pro-Cut 55’s are supplied with one 10 ft. #10 AWG 4-conductor input power cord already connected to the machine. When received from the factory, these machines are internally connected for the higher input voltage. Reconnection will be necessary if a lower input voltage is used.

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 two 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 screws on the near side of the switch can be loosened.

6. Loosen the screws and remove the existing 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, carefully feeding it under the aluminum bracket as you pull.

CORD INSTALLATION:

1. Feed the new cord through the cable connector

PRO-CUT 55

and into the machine, carefully feeding it under the aluminum bracket.

A-4

INSTALLATION

A-4

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. Angle the line switch so the screws on the switch can be tightened. Comply with the torque rating stamped on the switch.

5. Feed the line switch back into case front.

6. Replace the two screws that hold the line switch on to the case front.

7. Tighten the cable connector on the case back.

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

9. 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.

FRAME GROUNDING

The frame of the Pro-Cut 55 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.

WARNING

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 side 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.

USE ON ENGINE DRIVEN POWER SUPPLIES

The Pro-Cut 55 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 55 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.

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 55 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 55 Output Cut Thickness

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

PRO-CUT 55

A-5

INSTALLATION

GAS INPUT CONNECTIONS

Supply the PRO-CUT 55 with clean compressed air or nitrogen.

• Supply pressure must be between 80 psi and 150 psi.

• Pressure guage, located on the front of the machine, should be set to approximately 70 PSI for a 25 ft. torch and 75 PSI for a 50 ft. torch while gas is flowing (purging or cutting).

• Flow rate should be approximately 6.0 cfm (170 I/min.).

NOTE: Oil in the air supply to the PRO-CUT 55 can

cause severe problems. Use only a clean air supply.

A-5

• While it is recommended that an inline prefilter be placed ahead of each PRO-CUT, that may be in stalled in a shared air supply line, one large in line prefilter may instead be used to accommodate several PRO-CUT’s simultaneously. If a shared pre is desired, it must be rated to provide the necessary flow rate, as specified, to ensure proper operation of each of the PRO-CUT’s sharing a connection.

NOTE: When using nitrogen gas from a cylinder, the

cylinder must have a pressure regulator.

• Maximum psi from nitrogen gas cylinder to PROCUT 55 regulator should never exceed 150 psi.

• Install a hose between the nitrogen gas cylinder regulator and the PRO-CUT 55 gas inlet.

• Connect the gas supply to the PRO-CUT 55 regulator

• Compressed gas should be supplied to the fitting connection mounted on the filter at the rear of the machine. If necessary, this fitting can be removed allowing plumbing access through the 1/4” NPT input port on the filter body

• If compressed air is being used, it is highly recommended that an inline prefilter be installed in the air supply line ahead of the air connection to the PROCUT’S coalescing filter. While the coalescing filter is used to remove small amounts of oil and water aerosol particales from the air supply line, the prefilter can be used to remove larger particulates before they reach the coalescing filter element. This will prolong the life of the coalescing filter element by up to six times what it would be without the prefilter, and in turn, prolong the life of the PRO-CUT torch and consumables as well.

• A standard nominal 5 micron inline prefilter is rec ommended; however, for optimum performance, select a prefilter with a 3 micron absoluterating.If these filter ratings are unavailable, anything with a rating less than, or equal to, 20 micron would be acceptable to use. Inline filter elements will generally filter the air with little restriction to the airflow until the element is about 75% contaminated. After this point, there will bea noticeable pressure drop in the line. Filter elements should be replaced when a pressure drop of 8-10 psi is indicated; however, for optimum performance of the PRO-CUT, the filter element should be replaced at or before the pressure drop reaches 8 psi. Be sure to select a prefilter that will accommodate the necessary flow rating for the PROCUT as specified in the Installation section of this instruction manual under the Gas Input Connections heading.

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.

• Keep cylinder away from live electrical parts.

• Maximum inlet pressure 150 psi.

OUTPUT CONNECTIONS

Torch Connection

The Pro-Cut 55 is sent from the factory with a PCT 80 cutting torch. Additional cutting torches can be ordered from the K1571 series. Hand-held and mechanized torches come with 25' or 50’ cables.

All torches are connected to the Pro-Cut with a quick connect on the casefront for easy change over. This feature is excellent for changing between a hand cutting torch and a mechanized torch.

For more information on the torch and its components, refer to the PCT80 Operator’s Manual (IM588 latest version).

PRO-CUT 55

B-1

OPERATION

B-1

SAFETY PRECAUTIONS

Read and understand this entire section before operating the machine.

WARNING

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or electrode with skin or wet clothing.

• Insulate yourself from work and ground.

• Always wear dry insulating gloves.

FUMES AND GASES can be dangerous.

• Keep your head out of fumes.

• Use ventilation or exhaust to remove fumes from breathing zone.

WELDING, CUTTING and GOUGING SPARKS can cause fire or explosion

• Keep flammable material away.

• Do not weld, cut or gouge on containers that have held combustibles.

NOTE: All P.C. boards are protected by a moisture resistant coating. When the plasma cutter is operated, this coating will "bake off" of certain power resistors that normally operate at high temperatures emitting some smoke and odor for a short time. These resistors and the P.C. board beneath them may become darkened. This is a normal occurrence and does not damage the component or affect the machine performance.

DESCRIPTION

The Pro-Cut 55 is a constant current, continuous control plasma cutting power source. It provides superior and reliable starting characteristics, cutting visibility and arc stability. When cutting expanded metal, the Pro-Cut 55 out performs the competition due to its quick, clean response to arc transfers. The power supply design provides high transferto-cut distances which makes pierce cutting more reliable and with less nozzle wear. The control system has a safety mechanism to insure that the nozzle and electrode are in place before cutting or gouging. This is extremely important due to the high voltages involved.

The Pro-Cut 55 comes standard with an air regulator, coarse air filter, and pressure gauge. There are six different torch and cable systems to choose from: hand-held torch with 25' or 50' cable, machine and robotic torch both with 25' and 50' cable. Consumables are included so that cutting can begin right out of the box. Consumables can also be ordered as individual packages.

The Pro-Cut 55 initiates the plasma arc with a simple, yet reliable, touch start mechanism. This system eliminates many of the failure problems associated with hi-frequency start systems. The Pro-Cut 55 is capable of cutting with nitrogen or air.

ARC RAYS can burn.

• Wear eye, ear and body protection.

PLASMA ARC can injure

• Keep your body away from nozzle and plasma arc.

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

Observe additional Safety Guidelines detailed in the beginning of this manual.

PRO-CUT 55

The Pro-Cut 55 is controlled by a microprocessor-based control board. The machine performs rudimentary self troubleshooting when powered up which aids in field servicing.

PREHEAT TEMPERATURE FOR PLASMA CUTTING

Preheat temperature control is not necessary in most applications when plasma arc cutting or gouging. Preheat temperature control may be necessary on high carbon alloy steels and heat treated aluminum for crack resistance and hardness control. Job conditions, prevailing codes, alloy level, and other considerations may also require preheat temperature control. The following minimum preheat temperature is recommended as a starting point. Higher temperatures may be used as required by the job conditions and/or prevailing codes. If cracking or excessive hardness occurs on the cut face, higher preheat temperature may be required. The recommended minimum preheat temperature for plate thickness up to 1/2" (12.7mm) is 70°F (21.1°C).

B-2

OPERATION

B-2

USER RESPONSIBILITY

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

RECOMMENDED PROCESSES AND EQUIPMENT

The PRO-CUT 55 is capable of all cutting and gouging applications within its output capacity of 25 to 60 amps. These applications include thin gage sheet metal and expanded metal.

OPERATIONAL FEATURES AND CONTROLS

The PRO-CUT 55 comes with an ON/OFF POWER SWITCH, OUTPUT CURRENT CONTROL, PURGE BUTTON and a SAFETY RESET BUTTON.

- Input over voltage protection.

- Bright 3.0 second timed pilot arc.

- Purge momentary push button.

- Air regulator and pressure gage located on the front of machine for convenience.

- Parts-in-Place mechanism to detect proper installation of consumables and torch.

- Latching Parts-in-Place mechanism. Requires a positive operator reset.

- Automatic detection of faulty output control.

- In line coarse air filter.

- Preflow/Postflow timing. Preflow is eliminated if arc is re-initiated in Postflow.

- Thermostatic Protection.

- Solid state over-current protection.

- Works with pure nitrogen for cutting nonferrous materials.

- Reconnectable for multiple input voltages.

DESIGN FEATURES AND ADVANTAGES

The microprocessor controlled PRO-CUT 55 design makes plasma cutting and gouging tasks uncomplicated. This list of design features and advantages will help you understand the machine's total capabilities so that you can get maximum use from your machine.

- Light weight and portable design for industrial use.

- Continuous control, 25 - 60 amps.

- Reliable touch start mechanism for plasma arc initiation.

- Unique microprocessor controlled starting sequence for safe and consistent starting.

- Rapid arc transfer for fast cutting of expanded metal.

- High transfer distance for ease of use.

- Quick disconnect torch.

- Dead front display for machine status.

- Unique electrode and Vortech™ nozzle design for optimum cooling and long life.

- Swirl texture inside Vortech™ nozzle for better starting reliability and higher quality cuts.

- Unique drag cup design for durability and elimination of double arcing.

- Soft start of input filter capacitors at start up.

PRO-CUT 55

B-3

Lincoln's PRO-CUT 55

Mild Steel Cut Capacity Chart

Recommended Torch Travel Speed (IPM)

80% of Maximum Speed

100

0.000 0.125 0.250

0.375 0.500 0.625 0.750

Material Thickness

25 A

35 A

45 A

55 A

OPERATION

B-3

CUTTING CAPABILITY

The PRO-CUT 55 is rated at 55 amps, at 50% duty cycle on a 10 minute basis (runs 55 amps for 5 minutes, then idling for 5 minutes) or 40 amps, at 100% duty cycle (continuous use). If the duty cycle is exceeded, a thermal protector will shut off the output of the machine until it cools to the normal operating temperature.

Figure B.1 shows the cut capacity of the Pro-Cut 55 when cutting mild steel. The graph plots cut thickness vs. torch travel speed with a torch standoff of 0.15". Example: 0.25” material may be cut at a setting of 35 amps at an approximate speed of 38 IPM or at a setting of 45 amps at an approximate speed of 57 IPM or at a setting of 55 amps at an approximate speed of 62 IPM.

CONSUMABLE LIFE

The expected life for the Pro-Cut 55's electrode under normal operating conditions is approximately 50 to 60 minutes of cutting time at the machine’s maximum rated output. An erosion of approximately .060" in the electrode tip is typi-cal for the end of electrode life, however, the electrode may last longer. A sustained green and erratic arc will indicate definite electrode failure and both the electrode and nozzle should be replaced immediately.

It is recommended that consumables (electrode and nozzle) be replaced in complete sets. This will maximize the performance of the PRO-CUT system.

Figure B.1

PRO-CUT 55

OFF

XXXXXXXX XXXXXXXX XXXXXXXX XXXXXXXX

PRO-CUT 55

Torch Connector

Work Cable

Input Power Switch

Output Control Knob

Consumable Storage (behind door)

Status Board Indicators

Reset Button

Gas Purge Button

Gas Regulator Gauge

Gas Regulator Knob

3030

VERVERTICAL ANGLETICAL ANGLE FOR CUTTINGFOR CUTTING

CUT

TORCH AT 300ANGLE

TO PIERCE

ROTATE TO

ANGLE TO CUT

B-4

OPERATION

LIMITATIONS

Do not exceed output current and duty cycle rating of machine. Do not use the PRO-CUT 55 for pipe thawing.

CONTROLS AND SETTINGS

When preparing to cut or gouge, position the machine as close to the work as possible. Make sure you have all materials needed to complete the job and have taken all safety precautions. It is important to follow these operating steps each time you use the machine.

• Turn the machine's ON/OFF POWER SWITCH to OFF position.

• Connect the air supply to the machine.

1. Turn the main power and the machine

power switch on.

- The fan should start.

- The pre-charge circuit will operate for 4 seconds, then the green "Power" LED should turn on.

- If the "SAFETY" LED is lit, push the "Reset" button. If there is no problem, the LED will go off. If there is a problem, refer to Step "SAFETY LED" in this section.

- If any of the other LED’s remain lit and steady, refer to the troubleshooting section of the manual.

• Be sure that the work lead is clamped to the workpiece before cutting.

B-4

• Set the output current control knob at maximum position for high cutting speed and less dross formation. Reduce the current, if desired to reduce the kerf (cut) width, heat affected zone or travel speed as required.

2. GAS PRESSURE SETTINGS

• Push-in and hold the Purge button to check or set the gas pressure. Pull the pressure regulator cap out and turn it to set the pressure.

- Adjust the gas regulator for 70 PSI for 25’ torches or 75 PSI for 50’ torches.

- Release the Purge button.

- The gas will immediately turn off. The pressure gage may show an increase in pressure after the air turns off but this is normal. Do NOT reset the pressure while the air is NOT flowing.

3. PREPARING TO CUT

• When ready to cut, place the torch near the work, make certain all safety precautions have been taken and pull the trigger.

- The air will flow for a preflow time of 2 seconds and the pilot arc will start. (This is true unless the machine is in postflow, then the preflow time is skipped and the pilot arc will start immediately.)

- The pilot arc will run for 3.0 seconds and shut off unless the arc is brought in contact with the work and the arc is transferred. Avoid excessive pilot arc time by transferring the arc to the workpiece quickly to improve parts life.

- When the arc is brought within 1/4" from the work piece: the arc will transfer, the current will ramp up to the setting on the control panel, and the cut can last indefinitely (or until the duty cycle of the Pro-Cut is exceeded). Do not touch the nozzle to the work when cutting with the control panel setting above 45 amps or damage to the consumables will result.

• Pierce the work piece by slowly lowering the torch onto the metal at a 30 tor. This will blow the dross away from the torch tip. Slowly rotate the torch to vertical position as the arc becomes deeper.

angle away from the opera-

PRO-CUT 55

B-5

Direction of Travel

5° - 15°

10° - 20°

Arc Lag

Leading Angle

OPERATION

B-5

• Hold the nozzle standoff 1/8” (3.2mm) to 3/16” (4.7mm) above the workpiece during cutting. Do not let the torch nozzle touch the work or carry a long arc.

• Keep moving while cutting. Cut at a steady speed without pausing. Maintain the cutting speed so that the arc leg is 10° to 20° behind the travel direction.

• Use a 5° - 15° leading angle in the direction of the cut.

• Use the drag cup to maintain constant standoff for better cut quality and to protect the nozzle from spatter.

ANGLE

OF APPROACH

TORCH HELD AT

ANGLE

THROUGHOUT GOUG

ANGLE

MAINTAINED

THROUGHOUT

GOUGE

1. SAFETY LED

• If the "SAFETY" LED lights at any time, check the following:

WARNING

ELECTRIC SHOCK CAN KILL.

• Turn off machine at the disconnect switch on the front of the machine before tightening, cleaning or replacing consumables.

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

2. IN NORMAL OPERATION, THE “SAFETY” LED MAY TEMPORARILY ILLUMINATE AND CLEAR ITSELF AUTOMATICALLY WITHOUT DEPRESSING THE RESET BUTTON.

• Use the drag cup with a metal template to prevent nozzle double arcing.

• Finish the cut to be made and release the trigger.

• When the trigger is released, the arc will stop.

- The gas will continue to flow for 10 seconds of postflow. If the trigger is activated within this time period, the pilot arc will immediately restart.

• If the dross is difficult to remove, reduce the cutting speed. High speed dross is more difficult to remove than low speed dross.

• The right side of the cut is more square than the left as viewed along the direction of travel.

• Tilt the torch about 45° from the workpiece and hold the nozzle 1/8” (3.2mm) to 3/16” (4.7mm) above the workpiece for gouging.

• Clean spatter and scale from the nozzle and drag cup frequently.

• Check the assembly of the torch consumables. If they are not properly in place, the machine will not start. Make sure that the shield cup is hand

tight. Do not use pliers or over tighten.

• Check the conditions of the inside of the nozzle. If debris has collected, rub the electrode on the inside bottom of the nozzle to remove any oxide layer that may have built up. Refer to "Suggestions for Extra Utility from the PRO-CUT system".

• Check the condition of the electrode. If the end has a crater-like appearance, replace it along with the nozzle. The maximum wear depth of the electrode is approximately .060”. A green and erratic arc will indicate definite electrode failure and the electrode should be replaced immediately.

• Replace the nozzle when the orifice exit is eroded away or oval shaped.

• If the machine does not reset or continues to trip, consult the Troubleshooting Section.

• Use the proper cutting or gouging procedures referred to in Procedure Recommendations.

PRO-CUT 55

B-6

Torch Standoff

DRAG thru 1/16"

Standoff

Output Setting

Min. Range thru 45 Amps

Machine Output Setting

Torch Standoff

1/8" thru 3/16"

Standoff

Output Setting

45 Amps thru Max. Range

Machine Output Setting

OPERATION

B-6

PILOT ARC DISCUSSION

The PRO-CUT has a smooth, continuous pilot arc. The pilot arc is only a means of transferring the arc to the workpiece for cutting. Repeated pilot arc starts, in rapid succession, is not recommended as these starts will generally reduce consumable life. Occasionally, the pilot arc may sputter or start intermittently. This is aggravated when the consumables are worn or the air pressure is too high. Always keep in mind that the pilot arc is designed to transfer the arc to the workpiece and not for numerous starts without cutting.

When the pilot arc is started, a slight impulse will be felt in the torch handle. This occurrence is normal and is the mechanism which starts the plasma arc. This impulse can also be used to help troubleshoot a "no start" condition.

PROCEDURE RECOMMENDATIONS

When properly used, plasma arc cutting or gouging is a very economical process. Improper use will result in a very high operating cost.

Thick Sections of Metal

1. Output set above 45 amps.

• The best quality and consumable life will be obtained by holding the torch off the surface about 3/16". Too long an arc may compromise cut quality and consumable life. The nozzle should NOT be dragged on the work.

2. The nozzle should not be dragged on the work surface.

General - In All Cases

• Follow safety precautions as printed throughout

Thin Gauge Sheet Metal:

1. Output set below 45 amps.

• The nozzle may be dragged on the metal sur-

this operating manual and on the machine.

face, touching it lightly to the surface after piercing a hole. Current control should be set below the mid range.

• Dragging the nozzle on the work surface will result in shortened consumable life

• Use of the S22151 Drag Cup will maintain the

proper standoff and eliminate nozzle double arcing.

• If piercing is required, slowly lower the torch at

an angle of about 30° to blow the dross away from the torch tip and slowly rotate the torch to a vertical position as the arc becomes deeper. This process will blow a lot of molten metal and dross. Be careful! Blow the dross away from the torch, the operator and any flammable objects.

• Where possible, start the cut from the edge of

the work piece.

• Keep moving! A steady speed is necessary.

Do not pause.

• Do not allow torch cable or body to contact hot

surface.

2. Current Control should be set below the mid range.

• Do not allow cable or body to contact hot surface.

PRO-CUT 55

B-7

OPERATION

B-7

Suggestions for Extra Utility from the PRO-CUT System:

WARNING

ELECTRIC SHOCK CAN KILL.

• Turn off machine at the disconnect switch on the front of the machine before tightening, cleaning or replacing consumables.

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

1. Occasionally an oxide layer may form over the tip of the electrode, creating an insulating barrier between the electrode and nozzle. This will result in the tripping of the Pro-Cut's safety circuit. When this happens turn the power off, remove the nozzle and electrode and use the electrode to rub against the inside bottom surface of the nozzle. This will help remove any oxide buildup. Replace the nozzle, turn on the power and continue cutting. If the Parts-in-Place circuit continues to trip after cleaning the consumables, then replace them with a new set. Do not continue to try and cut with excessively worn consumables as this can cause damage to the torch head and will degrade cut quality.

higher or lower pressure will cause turbulence in the plasma arc, eroding the orifice of the nozzle tip.

i. Use only Lincoln consumable parts. These

parts are patented and using any other replacement consumables may cause damage to the torch or reduce cut quality.

2. To improve consumable life, here are some sug-

gestions that may be useful:

a. Never drag the nozzle on the work surface if

the output control knob is above 45 amps.

b. Make sure the air supply to the Pro-Cut is

clean and free of oil. Use several extra in line filters if necessary.

c. Use the lowest output setting possible to make

a good quality cut at the desired cut speed.

d. Minimize dross buildup on the nozzle tip by

starting the cut from the edge of the plate when possible.

e. Pierce cutting should be done only when nec-

essary. If piercing, angle torch about 30° from the plane perpendicular to the work piece, transfer the arc, then bring the torch perpendicular to the work and begin parallel movement.

f. Reduce the number of pilot arc starts without

transferring to the work.

g. Reduce the pilot arc time before transferring

to the work.

h. Set air pressure to recommended setting. A

PRO-CUT 55

C-1

ACCESSORIES

C-1

ALWAYS USE GENUINE LINCOLN ELECTRIC ELECTRODES AND VORTECH™ NOZZLES

• Only Genuine Lincoln Electric consumables yield

the best cutting performance for the PRO-CUT 55.

• The patented VORTECH™ nozzle provides an

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

this capability or can match its performance.

S22151 - Drag Cup - The drag cup protects the torch by preventing the torch from touching the workpiece.

K1571 Series - PCT 80 Torches come in 25’ and 50’ lengths in either hand held or mechanized versions.

K1678-1 MACHINE INTERFACE KIT

This kit is compatible with the present models of the Pro-Cut 55. Machines having code numbers 10473 and 10474 may require their Output PC Board to be upgraded to a G3326-2 board.

This kit provides the necessary hardware and instructions to install a14 Pin MS Type remote connector into the machine. This connector provides provisions for the following interface signals between the Pro-Cut 55 and the controller.

ARC START:

The Arc Start circuit allows for triggering of the power source to commence cutting. This circuit can be accessed through pins K and M of the 14 pin MS connector. The circuit has a 17 VDC nominal open circuit voltage and requires a dry contact closure to activate.

GENERAL OPTIONS / ACCESSORIES

The following options/accessories are available for your PRO-CUT 55 from your local Lincoln Distributor.

K1600-1 Undercarriage - A valet style undercarriage with pull-out handle for machine only. Provides Torch and Work Cable storage.

S22147-043 - VORTECH™ nozzle with an .043” (1.2 mm) Orifice

S22147-068 - VORTECH™ nozzle with an .068” (1.7 mm) Orifice

S22149 - Electrode - replacement electrodes for cutting.

S22150 - Shield Cup - This shields the torch tip and provides more visibility to the workpiece than the drag cup.

• Note: The shield cup does not prevent the torch tip

from touching the workpiece.

ARC INITIATED:

The Arc Initiated circuit provides information as to when a cutting arc has transferred to the work piece. This circuit can be accessed through pins I and J of the 14 pin MS connector. The circuit provides a dry contact closure when the arc has transferred. Input to this circuit should be limited to 0.3 A for either 120VAC or 30VDC.

ARC VOLTAGE:

The Arc Voltage circuit can be used for activating a torch height control. This circuit can be accessed through pins D and G of the 14 pin MS connector. The circuit provides full electrode to work arc voltage (no voltage divider, 335VDC maximum).

Arc Start

K=2A

M=4A

D=344

Arc Voltage

14-PIN BOX RECEPTACLE, FRONT VIEW

J=347

I=348

G=343

Arc Initiated

Users wishing to utilize the Machine Interface can order a K867 Universal Adapter (please adhere to the pin locations stated above) or manufacture a 14 pin MS connector cable assembly.

PRO-CUT 55

D-1

UPPER

CAPACIT OR TERMINALS

LOWER CAPACITOR TERMINALS

INSULATED

GLOVES

INSULATED

PLIERS

POWER

RESISTOR

POWER

BOARD

RIGHT SIDE OF MACHINE

INPUT FILTER CAPACIT OR DISCHARGE PROCEDURE

MAINTENANCE

5. Locate the two capacitor terminals (large hex head cap screws) on the top and bottom of the Power P.C. Board shown in Figure D.1.

D-1

1. Turn off input power or disconnect input power lines.

2. Remove the 5/16" hex head screws from the side and top of the machine and remove wrap-around machine cover.

3. Be careful not to make contact with the capacitor terminals that are located on the top and bottom of the Power Board on the right side of the machine.

4. Obtain a high resistance and high wattage resistor (25-1000 ohms and 25 watts minimum). This resistor is not supplied with machine. NEVER USE A SHORTING STRAP FOR THIS PROCEDURE.

FIGURE D.1 — LOCATION OF INPUT FILTER CAPACITOR TERMINALS.

ELECTRIC SHOCK can kill.

• Have an electrician install and service this equipment.

• Turn the input power off at the fuse box before working on equipment.

• Do not touch electrically hot parts.

• Prior to Performing preventative main-

tenance, perform the following capacitor discharge procedure to avoid electric shock.

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

6. Use electrically insulated gloves and insulated pliers. Hold body of the resistor and connect resistor leads across the two capacitor terminals. Hold resistor in place for 10 seconds. DO NOT TOUCH CAPACITOR TERMINALS WITH YOUR BARE HANDS.

7. Repeat discharge procedure for the other capaci-

tor .

8. Check voltage across terminals of all capacitors with a DC voltmeter. Polarity of capacitor terminals is marked on PC board above terminals. Voltage should be zero. If any voltage remains, repeat this capacitor discharge procedure.

WARNING

PRO-CUT 55

D-2

MAINTENANCE

D-2

ROUTINE MAINTENANCE

1. Keep the cutting or gouging area and the area around the machine clean and free of combustible materials. No debris should be allowed to collect which could obstruct air flow to the machine.

2. Every 6 months or so, the machine should be cleaned with a low pressure airstream. Keeping the machine clean will result in cooler operation and higher reliability. Be sure to clean these areas:

- Power, Output and Control printed circuit boards and heat sinks

- Power switch

- Main Transformer

- Input Rectifier

3. Examine the sheet metal case for dents or breakage. Repair the case as required. Keep the case in good condition to insure that high voltage parts are protected and correct spacings are maintained. All external sheet metal screws must be in place to insure case strength and electrical ground continuity.

4. Check the air regulator filter to be sure it does not become clogged. The air filter on the machine is self draining and will not have to be emptied.

5. Check the filter element every several months to see if it is clogged (weekly in very dirty environments). Replace if necessary by first removing the two screws that attach the filter cage to the back panel assembly, then slide the cage away from the back of the machine and remove. Next, twist the clear filter bowl until it comes off (be careful not to lose the o-ring seated at the top of the bowl threads). Unscrew the filter element and replace with new element. Assemble parts in reverse order as described above.

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

PERIODIC MAINTENANCE

WARNING

ELECTRIC SHOCK CAN KILL.

• Turn off machine at the disconnect switch on the front of the machine before tightening, cleaning or replacing consumables.

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

Change consumables as required.

1. Thermal Protection Two thermostats protect the machine from excessive

operating temperatures. Excessive temperatures may be caused by a lack of cooling air or operating the machine beyond the duty cycle and output rating. If excessive operating temperatures should occur, the yellow thermal LED will light and the thermostat will prevent output voltage or current.

Thermostats are self-resetting once the machine cools sufficiently. If the thermostat shutdown was caused by excessive output or duty cycle and the fan is operating normally, the Power Switch may be left on and the reset should occur within a 15 minute period. If the fan is not turning or the air intake louvers were obstructed, then the power must be switched off and the fan problem or air obstruction must be corrected.

2. Filter Capacitor Conditioning (Pro-Cut 55, 400-460 or 460-575 VAC only)

A protection circuit is included to monitor the voltage across filter capacitors C1 and C2. In the event that the capacitor voltage is too high, the protection circuit will prevent output. The protection circuit may prevent output providing all these circumstances are met:

a. Machine is connected for 400-460 or 460-575

VAC input.

b. Machine did not have power applied for many

months.

c. Machine will not produce output when power is

first switched on.

If these circumstances apply, the proper action is to switch the machine on and let it idle for up to 30 minutes. This is required to condition the filter capacitors after an extended storage time. The protection circuit will automatically reset once the capacitor conditioning and resultant voltage levels are acceptable. It may be necessary to turn the power switch off and back on again after this period.

PRO-CUT 55

E-1

TROUBLESHOOTING

HOW TO USE TROUBLESHOOTING GUIDE

WARNING

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

__________________________________________________________________________

E-1

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

Step 1. LOCATE PROBLEM (SYMPTOM).

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

Step 2. POSSIBLE CAUSE.

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

WARNING

ELECTRIC SHOCK CAN KILL.

• Turn off machine at the disconnect switch on the front of the machine and remove main power supply connections before doing any troubleshooting

Step 3. RECOMMENDED COURSE OF ACTION

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

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

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

E-2

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

E-2

No Status indicators light and the fan does not operate 5 seconds after the power switch is turned on.

No Status indicators light 5 seconds after the power switch is turned on, but the fan operates.

1. Check the input power to be sure it is on.

2. Check the power line fuses and machine connection.

3. Disconnect input power at fuse panel and check line switch continuity. Replace line switch if bad.

4. Auxiliary transformer may be faulty.

1. Auxiliary transformer may be faulty.

2. Disconnect input power from the machine. Check that connectors on harness between Control Bd. and Display Bd. are properly seated.

3. Possible faulty Control Board.

If all recommended possible areas of misadjustment have been checked and the problem persists, Contact

your local Lincoln Authorized Field Service Facility.

All Status indicators remain lit immediately after power up.

All Status indicators begin to blink within 5 seconds after power up.

1. The microprocessor has experienced a memory fault. Consult local Lincoln Field Service shop.

1. Turn power off. Make sure reconnect is positioned correctly for the input voltage used. Wait at least 1 minute after power down before re-connecting the machine. Reconnect machine,then restore power to Pro-Cut.

2. Possible faulty Primary board.

3. Possible faulty Control board.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

PRO-CUT 55

E-3

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

E-3

The Pro-Cut powers up properly but there is no response when the trigger is pulled and only the POWER LED is lit.

1. Press Purge button on the front of the Pro-Cut. If air does not flow, then:

a. Auxiliary transformer may be

faulty.

b. The main gas solenoid assem-

bly may be faulty. Check or replace.

c. Possible faulty Output Power

board.

d. Possible faulty Control board.

2. (check for continuity from the bulkhead connector to the molex) See Wiring Diagram.

3. Remove the handles (or barrel) of the torch and examine all the connections. Pay attention to location of electrode lead mounting at back of torch head, broken trigger and solenoid leads.

If all recommended possible areas of misadjustment have been checked and the problem persists, Contact

your local Lincoln Authorized Field Service Facility.

4. Check for proper trigger switch operation. Remove the torch cable assembly from the Pro Cut and test for continuity between 9 and 1 at the quick connect when the trigger switch is depressed and no continuity when the switch is not depressed. Replace the trigger switch or torch cable if defective.

5. Possible faulty Control board.

6. Possible faulty Output Power board.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

PRO-CUT 55

E-4

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

E-4

When the trigger is pulled air begins to flow, but there is no pilot arc after at least 3 seconds.

The air begins to flow and there is a very brief arc that snaps out consistently with repeated trigger pulls.

Check the torch consumables to be sure they are not dirty or greasy, and are in good shape. Replace the consumables if necessary. Make sure the air pressure is set at 70 psi (75 psi for a 50 ft. torch).

2. Make sure there are no kinks or restrictions for air flow in the torch cable. Replace cable as needed.

3. If a slight thump cannot be felt in the torch when the trigger is pulled, check for loose connection in the torch head and solenoid assembly.

4. With machine turned off - input power removed, and torch and consumables connected - measure resistance on Output Power board between B1 and B21. If >10Ω, possible fault in torch and cable assembly.

5. Possible fault in Output board.

1. Check the torch consumables to be sure they are in tight, not dirty or greasy and in good shape. Replace if necessary.

If all recommended possible areas of misadjustment have been checked and the problem persists, Contact

your local Lincoln Authorized Field Service Facility.

2. Make sure the air pressure is set at 70 psi (75 psi for a 50 ft. torch).

Possible fault in Output Power board.

The arc starts but sputters badly.

1. Check the torch consumables to be sure they are in tight, not dirty or greasy and in good shape. Replace if necessary.

2. Check air supply for oil or a great deal of water. If there is oil or a great deal of water, the air must be filtered or the machine switched to nitrogen or bottled air.

3. Make sure the air pressure is set at 70 psi.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

PRO-CUT 55

E-5

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

E-5

Pilot arc starts but will not transfer when brought near work.

1. Check work lead connection for clean, secure connection.

2. Plasma will only cut conductive material. Do not attempt to cut fiberglass, plastic, rubber, PVC or any other non-conductive material.

3. Make sure work piece is clean and dry. Remove any scale, rust or dross.

4. Check all connections to Output board.

5. Possible faulty Control board.

If all recommended possible areas of misadjustment have been checked and the problem persists, Contact

your local Lincoln Authorized Field Service Facility.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

PRO-CUT 55

E-6

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

STATUS BOARD INDICATORS

E-6

SYMPTOM

Machine is unresponsive immediately after power-up.

The Air Low LED is lit

The Safety LED is flashing

The Safety LED is lit and steady

CHECK

1. There is a 4 second soft start period for pre-charging the input filter capacitors. Wait until that time is up. The Power LED will light when ready. If not, refer to the first part of this section.

1. Make sure there is at least 80 psi connected to the gas connection at the back of the machine.

2. Press the Purge button and set the regulator to 70 psi. The pressure may increase when air stops flowing but this is normal. Do not reset the pressure while the air is OFF.

3. Possible faulty Pressure Switch.

4. Possible faulty Control board.

1. Make sure there is a Lincoln torch and cable assembly connected properly to the Pro-Cut bulk head connector.

2. Check consumables for proper installation or excessive wear. Replace if excessively worn. If not, use a piece of fine emery cloth to remove any oxide buildup on the tip of the electrode.

1. Press the Reset button. If torch and consumables are properly installed, the Safety LED should turn off. Normal cutting or gouging can resume.

The Thermal LED is lit

The “Ready”, “Air Low” and “Thermal” LED’s are flashing

1. The machine's thermostat has tripped due to exceeded duty cycle limits. Do NOT turn the power off. Allow the machine to cool for 15 - 30 minutes and the thermostat will reset itself.

2. The machine's air louvers or fans are obstructed such that air cannot flow to properly cool the machine. Remove any foreign material that may block air flow. Blow the machine out with a clean, dry air stream.

3. Possible faulty Control board.

1. This is typically caused by connecting the auxiliary transformer input tap to the wrong voltage. Turn machine OFF and change lead to correct input voltage at reconnect panel.

2. Possible faulty Control P. C. Board.

PRO-CUT 55

E-7

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-7

CONSUMABLE RELATED SAFETY LED TROUBLESHOOTING

A. If the Safety LED is LIT AND STEADY, perform the following:

1. If the reset button (when pressed) does not turn the Safety LED off, the reset button or associated wiring may be faulty. See the wiring diagram.

• Press the reset button. If the torch and consumables are properly installed, the Safety LED should turn off.

2. If this has occurred numerous times, clean consumables with a piece of fine emery cloth to remove any oxide buildup on the tip of the electrode, or try replacing the electrode and nozzle.

• Try to recount the number of times that the Safety LED has come on lit and steady with this particular set of consumables.

If problems persist after completing steps 1 and 2,

contact your local Lincoln Authorized Field Service Facility.

_________________________________________________________________________________________

B. If the Safety LED is FLASHING, perform the following:

1. Check the condition of the electrode. The maximum wear depth in the center of the electrode tip is approximately .060" relative to the surrounding tip. A green and erratic arc will indicate definite electrode failure as explained in the "Consumable Life" section of this manual.

• Replace both electrode and nozzle if electrode is excessively worn. Otherwise, use a piece of fine emery cloth to remove any oxide buildup on the tip of the electrode. Even if consumables appear to be in good working order, it is possible that they are the cause of the problem. Try replacing.

2. Check the conditions of the inside of the nozzle. Make sure that both the electrode and nozzle are not dirty, oily, or corroded.

• If debris has collected, rub the electrode on the inside bottom of the nozzle to remove any oxide layer that may have built up. If problems persist, try replacing consumables.

3. Remove consumables from torch and check inside of torch head for contamination. Check incoming airflow for contaminants.

• If torch head is contaminated, take a dry cotton swab and clean out the pollutants. If needed, replace air filter and check/change air supply. For more information, refer to the "Gas Input Connections" section in the manual.

4. Make sure there is a Lincoln PCT 80 torch connected properly to the Pro-Cut 55 and that the consumables are properly installed. Make sure the shield cup is hand tight. Do not use pliers or over-tighten.

• After verifying that the torch and consumables are properly set in place.

NOTE: Make sure that consumables are Lincoln Electric brand consumable parts. These parts are patented and

using any other replacement consumables may cause damage to the torch or reduce cut quality. Also be sure to check that the nozzle is the correct part number (as identified on the top and side of the nozzle)

for the Pro-Cut being used.

If problems still persists after completing steps 1 thru 4,

contact your local Lincoln Authorized Field Service Facility.

_________________________________________________________________________________________

PRO-CUT 55

F-1

310

ELEC

xxxxxxx

CONTROL

S4 PRIMARY

LEFT SIDE OF MACHINE

360

365

J33

J31

RESET

J5,J22

217

216

J30

223

J4,J10,

PSI_SET

J1,J20,

J33

POWER

12V

24V

203A

206

1200/450

POWER

503

277A

221

400-

460VAC

200-

ELECTRICAL SYMBOLS PER E1537

RECONNECT

L10942

18V

INPUT

WIRING DIAGRAM PRO-CUT 55 Codes 10475, 10476, 10571 & 10572

AUXILIARY

TRANSFORMER

J22

220-

230V

440-

460V

200-

208V

380-

415V

BK-OUT

BK-IN

219

R = RED

(VIEWED FROM COMPONENT SIDE OF BOARD)

W = WHITE

CONNECTOR CAVITY NUMBERING SEQUENCE

G = GREEN

B = BLACK

COLOR CODE:

DISPLAY

WORK

364

369

10K

CW (MAX)

277

276

366

361

J20

J32

U = BLUE

N = BROWN

Y = YELLOW

X40

X10

X20

X30

3XFMR2MAIN

0.6A

SLOW BLOW

207

567

123

11 TRIGGER

12 GND

3 IGBT

2,6 PSI SWITCH

10 ELEC SOL

9 AIR SOL

TSTAT

RELAY

++VOLT

P_XFMR

BASE

FR-OUT

PROTECTIVE BONDING CIRCUIT

CASE FRONT

BK-IN

BK-OUT

221

223

275

277

276

275

302

215

214

213

212

202

210

218

206

217

216

203

207

203

202

202A

312

J21

64 9

TP3

TP2

TP1

INPUT

BRIDGE

209

207A

FRONT OF MACHINE

1. FOR MACHINES SUPPLIED WITH INPUT CABLE

FOR SINGLE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE.

CONNECT BLACK & WHITE LEADS TO SUPPLY CIRCUIT.

WRAP RED LEAD WITH TAPE TO PROVIDE 600V. INSULATION.

FOR THREE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE.

CONNECT BLACK, RED & WHITE LEADS TO SUPPLY CIRCUIT.

2. FOR MACHINES NOT SUPPLIED WITH INPUT CABLE

FOR SINGLE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES.

CONNECT TERMINALS U & W TO SUPPLY CIRCUIT.

FOR THREE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES.

CONNECT TERMINALS U, V & W TO SUPPLY CIRCUIT.

THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT

COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER.

N.B. SINCE COMPONENTS OR CIRCUITRY OF A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING

CONNECTION SHOWN IS FOR 440-460V OPERATION.

N.C. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE.

N.D. C1 AND C2 CAPACITORS ARE A MATCHED SET.

365

N.A.

J30

FAN

NOTES:

+15V

READY LED

277B

18V18V

7,8 ELEC SHUNT (TWIST PR)

4,5 XFER SHUNT (TWIST PR)

RIGHT SIDE OF MACHINE

PER

N.A.

306

303

302

309

230VAC

203A

N.C.

MOTORS

401

FAN

OUTPUT

PC BOARD

FAN

361

364

360

404

369

366

401

B21

L1 CHOKE

J40

AIR

SOLENOID

PRESSURE

CONTROL

215

210

214

219

213

218

212

277A

306

503

209

205

501

RELAY

505

208

502

++VOLT

506

P_XFMR

507

J10

201

204

207A

202A

344

2 9

309 1 8

303

312

2 7

2 5

OUTPUT

1,4=24V

13 IGBT

14 GND

1,2 TRIGGER

4 ELECTRODE

5,6 AIR SOL

J32

12V

3 NOZZLE

X20

X40

7,8 ELEC SOL

10 WORK

2 ELEC SOL

8 AIR SOL

3 TRIGGER

POT

502

FR-IN

CURRENT

1200/450

TRANSFORMER

1 3

2 4

404

201

251

8-18-2000F

LOW_PSI LED

POT WIPER

RESET

GND

THERMAL LED

RESET LED

PSI SET

18V

XFER

REAR OF MACHINE

xxxxxxx

205

FR-OUT

FR-IN

310

344

3 8

2 7

505

501

506

507

J2,J21,

J31

208

204

DIAGRAMS

F-1

PRO-CUT 55

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside

the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.

F-2

DIAGRAMS

F-2

PRO-CUT 55

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside

the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.

F-3

LEFT SIDE OF MACHINE

J5,J22,J36

J35

J4,J10,

J1,J20,

J33

ELECTRICAL SYMBOLS PER E1537

L12067

WIRING DIAGRAM (CODES 11013 & 11014)

R = RED OR PINK

(VIEWED FROM COMPONENT SIDE OF BOARD)

W = WHITE

CONNECTOR CAVITY NUMBERING SEQUENCE

G = GREEN

B = BLACK OR GRAY

COLOR CODE:

J38

U = BLUE

N = BROWN

Y = YELLOW

BASE

PROTECTIVE BONDING CIRCUIT

CASE FRONT

1. FOR MACHINES SUPPLIED WITH INPUT CABLE

FOR THREE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE.

CONNECT BLACK, RED & WHITE LEADS TO SUPPLY CIRCUIT.

2. FOR MACHINES NOT SUPPLIED WITH INPUT CABLE

FOR THREE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES.

CONNECT TERMINALS U, V & W TO SUPPLY CIRCUIT.

THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT

COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER.

N.B. SINCE COMPONENTS OR CIRCUITRY OF A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING

N.D. CONNECTION SHOWN IS FOR 575V OPERATION.

N.C. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE.

N.A.

NOTES:

OUTPUT

PC BOARD

J40

J2,J21,

J30,J37

J39

503

213

506

214

502

218

215

210

16815

302

312

231

202

201

201A

460VAC

231A

507

506

505

POWER

53 8

12V

24V

J40

215

210

214

219

213

218

277A

306

212

248

217

216

209

J10

501

306

303

302

CONTROL

309

N.C.

360

1200/450

440-

460V

OUTPUT

501

219

DISPLAY

WORK

364

369

10K

CW (MAX)

277

276

366

361

J20

ELEC

XFER

IN_SENSE

ELEC

J11

502

123

9 AIR SOL

TSTAT

10 ELEC SOL

P_XFMR

++VOLT

RELAY

321

2,6 PSI SWITCH

11 TRIGGER

12 GND

3 IGBT

K-

OUT

18V

LOW_PSI LED

POT WIPER

RESET

GND

THERMAL LED

SAFETY LED

PSI SET

21713212

275

507

J21

AUXILIARY

TRANSFORMER

U64

TP3

TP2

TP1

INPUT

BRIDGE

209

365

N.A.

PER

INPUT

221

223

221

}

275

276

277

241A

+15V

READY LED

277B

18V18V

7,8 ELEC SHUNT (TWIST PR)

4,5 XFER SHUNT (TWIST PR)

X40

0.6A

RELAY

P_XFMR

++VOLT

RESET

SOLENOID

216

223

PSI_SET

277A

MOTORS

401

FAN

404

401

B21

CHOKE

SLOW BLOW

550-

575V

-I

RIGHT SIDE OF MACHINE

440-

207A

FR-O

1200/450

354

310

N N

205

X20

X40

248A

241

201

201A

231

FAN

404

503 3

2 5

204

241

xxxxxxx

205

204

575VAC

241

550-

S4 PRIMARY

RECONNECT

J33

208

18V

xxxxxxx

FR-

505

CONTROL

PRESSURE

AIR

206

202

POWER

208

238

248

MAIN

XFMR

X20

X30

X10

TRANSFORMER

CURRENT

207A

J22

543

POT

1 6

3 8

4 9

FR-IN

238

211

RESET LED

211

4 IGBT

3 TRIGGER

2 ELEC SOL

1,2 TRIGGER

J39

4,8 OK TO MOVE

2,3 = 24V

J36

354

312

310

303

364

369

366

361

348

347

283

309

514

172

344

360

343

365

1,7 TRIGGER

3,4 AIR SOL

5,6 ELEC SOL

1 NOZZLE

J38

5, 10 ELECTRODE

3,8 WORK

11,12 = 12V

OUTPUT

401

J35

J37

xxxxxxx

J30

1 AIR SOL

6 GND

223

DIAGRAMS

F-3

PRO-CUT 55

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside

the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.

F-4

ELEC

xxxxxxx

CONTROL

S4 PRIMARY

LEFT SIDE OF MACHINE

360

J33

J37

RESET

J5,J22,J36

217

216

J35

223

J4,J10,

PSI_SET

J1,J20,

J33

POWER

12V

24V

203A

206

1200/450

POWER

263

503

277A

221

400-

460VAC

200-

ELECTRICAL SYMBOLS PER E1537

RECONNECT

L12066

18V

INPUT

WIRING DIAGRAM (CODES 11011, 11012, 11015 & 11016)

AUXILIARY

TRANSFORMER

J22

220-

230V

01/2

6/2004460V

200-

208V

380-

415V

219

R = RED OR PINK

(VIEWED FROM COMPONENT SIDE OF BOARD)

W = WHITE

CONNECTOR CAVITY NUMBERING SEQUENCE

G = GREEN

B = BLACK OR GRAY

COLOR CODE:

DISPLAY

WORK

364

369

10K

CW (MAX)

277

276

366

361

J20

J38

U = BLUE

N = BROWN

Y = YELLOW

X40

X10

X20

XFMR2MAIN

0.6A

SLOW BLOW

207

123

11 TRIGGER

12 GND

3 IGBT

2,6 PSI SWITCH

10 ELEC SOL

9 AIR SOL

TSTAT

RELAY

++VOLT

P_XFMR

BASE

PROTECTIVE BONDING CIRCUIT

CASE FRONT

-IN

-O

221

223

275

277

276

275

302

215

214

213

212

202

210

218

206

217

216

203

207

203

202

202A

312

J21

64 9

TP3

TP2

TP1

INPUT

BRIDGE

209

207A

1. FOR MACHINES SUPPLIED WITH INPUT CABLE

FOR SINGLE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE.

CONNECT BLACK & WHITE LEADS TO SUPPLY CIRCUIT.

WRAP RED LEAD WITH TAPE TO PROVIDE 600V. INSULATION.

FOR THREE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE.

CONNECT BLACK, RED & WHITE LEADS TO SUPPLY CIRCUIT.

2. FOR MACHINES NOT SUPPLIED WITH INPUT CABLE

FOR SINGLE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES.

CONNECT TERMINALS U & W TO SUPPLY CIRCUIT.

FOR THREE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES.

CONNECT TERMINALS U, V & W TO SUPPLY CIRCUIT.

THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT

COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER.

N.B. SINCE COMPONENTS OR CIRCUITRY OF A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING

CONNECTION SHOWN IS FOR 440-460V OPERATION.

N.C. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE.

N.D. C1 AND C2 CAPACITORS ARE A MATCHED SET.

365

N.A.

J35

FAN

NOTES:

+15V

READY LED

277B

18V18V

7,8 ELEC SHUNT (TWIST PR)

4,5 XFER SHUNT (TWIST PR)

RIGHT SIDE OF MACHINE

PER

N.A.

306

303

302

309

230VAC

203A

N.C.

MOTORS

401

FAN

OUTPUT

PC BOARD

FAN

404

401

B21

CHOKE

J40

AIR

SOLENOID

PRESSURE

CONTROL

215

210

214

219

213

218

212

277A

306

6167

503

209

205

501

RELAY

505

208

502

++VOLT

506

P_XFMR

507

J10

201

204

207A

202A

N N

OUTPUT

11,12 = 12V

3,8 WORK

5, 10 ELECTRODE

J38

1 NOZZLE

X20

X40

5,6 ELEC SOL

3,4 AIR SOL

1,7 TRIGGER

POT

502

FR-IN

CURRENT

1200/450

TRANSFORMER

2 4

404

201

251

}

LOW_PSI LED

POT WIPER

RESET

GND

THERMAL LED

SAFETY LED

PSI SET

18V

XFER

xxxxxxx

205

FR-O

FR-IN

310

354

4 9

3 8

505

501

506

507

J2,J21,

J37,J39

208

204

J39

211

RESET LED

211

365

343

360

2 6

344

4 9

3 8

2716

415

309

4 9

382

1 6

347

348

361

366

369

364

303

310

312

354

J36

2,3 = 24V

4,8 OK TO MOVE

J39

1,2 TRIGGER

2 ELEC SOL

3 TRIGGER

4 IGBT

J30

1 AIR SOL

6 GND

223

DIAGRAMS

F-4

PRO-CUT 55

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside

the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.

F-5

11.00

25.94

19.502.95

DIMENSION PRINT PRO-CUT 55

10-31-97D

M18806

OFF

XXXX XXXX

XXXX

XXXX XXXX

XXXX

PRO-CUT 55

DIAGRAMS

F-5

PRO-CUT 55

NOTES

PRO-CUT 55

NOTES

PRO-CUT 55

WARNING

Spanish

AVISO DE

PRECAUCION

● Do not touch electrically live parts or

electrode with skin or wet clothing.

● Insulate yourself from work and

ground.

● No toque las partes o los electrodos

bajo carga con la piel o ropa mojada.

● Aislese del trabajo y de la tierra.

● Keep flammable materials away.

● Mantenga el material combustible

fuera del área de trabajo.

● Wear eye, ear and body protection.

● Protéjase los ojos, los oídos y el

cuerpo.

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

● Ne laissez ni la peau ni des vête-

ments mouillés entrer en contact avec des pièces sous tension.

● Isolez-vous du travail et de la terre.

● Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem Körper oder feuchter Kleidung!

● Isolieren Sie sich von den

Elektroden und dem Erdboden!

● Não toque partes elétricas e elec-

trodos com a pele ou roupa molhada.

● Isole-se da peça e terra.

● Gardez à l’écart de tout matériel

inflammable.

● Entfernen Sie brennbarres Material!

● Mantenha inflamáveis bem guarda-

dos.

● Protégez vos yeux, vos oreilles et

votre corps.

● Tragen Sie Augen-, Ohren- und Kör-

perschutz!

● Use proteção para a vista, ouvido e

corpo.

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

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

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

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

● Keep your head out of fumes.

● Use ventilation or exhaust to

remove fumes from breathing zone.

● Turn power off before servicing.

● Do not operate with panel open or

guards off.

WARNING

● Los humos fuera de la zona de res-

piración.

● Mantenga la cabeza fuera de los

humos. Utilice ventilación o aspiración para gases.

● Gardez la tête à l’écart des fumées.

● Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zones de travail.

● Vermeiden Sie das Einatmen von

Schweibrauch!

● Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

● Mantenha seu rosto da fumaça.

● Use ventilação e exhaustão para

remover fumo da zona respiratória.

● Desconectar el cable de ali-

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

● Débranchez le courant avant l’entre-

tien.

● Strom vor Wartungsarbeiten

abschalten! (Netzstrom völlig öffnen; Maschine anhalten!)

● Não opere com as tampas removidas.

● Desligue a corrente antes de fazer

serviço.

● Não toque as partes elétricas nuas.

● No operar con panel abierto o

guardas quitadas.

● N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de protection enlevés.

● Anlage nie ohne Schutzgehäuse

oder Innenschutzverkleidung in Betrieb setzen!

● Mantenha-se afastado das partes

moventes.

● Não opere com os paineis abertos

ou guardas removidas.

Spanish

AVISO DE

PRECAUCION

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

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

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

Lincoln Electric IM637-A User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual