Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thoughtful operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
TM
March, 2005
55
10571, 10572, 10475, 10476, 10586 and 10587
11011, 11012, 11013, 11014, 11015 and 11016
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
i
SAFETY
i
WARNING
PLASMA CUTTING or GOUGING can be hazardous.
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN
AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040,
Miami, Florida 33135 or CSA Standard W117.2.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
ELECTRIC SHOCK can
kill.
1.a. The electrode and work (or ground) circuits
are electrically “hot” when the power source is on.
Do not touch these “hot” parts with your bare skin
or wet clothing. Wear dry, hole-free gloves to
insulate hands.
1.b. When the power source is operating voltages in excess of
250 volts are produced. This creates the potential for serious
electrical shock - potentially even fatal.
1.c. Insulate yourself from work and ground using dry insulation.
When cutting or gouging in damp locations, on metal framework such as floors, gratings or scaffolds and when in positions such as sitting or lying, make certain the insulation is
large enough to cover your full area of physical contact with
work and ground.
1.d. Always be sure the work cable makes a good electrical connection with the metal being cut or gouged. The connection
should be as close as possible to the area being cut or
gouged.
1.e. Ground the work or metal to be cut or gouged to a good electrical (earth) ground.
1.f. Maintain the plasma torch, cable and work clamp in good,
safe operating condition. Replace damaged insulation.
1.g. Never dip the torch in water for cooling or plasma cut or
gouge in or under water.
1.h. When working above floor level, protect yourself from a fall
should you get a shock.
1.i. Operate the pilot arc with caution. The pilot arc is capable of
burning the operator, others or even piercing safety clothing.
1.j. Also see Items 4c and 6.
ARC RAYS can burn.
2.a. Use safety glasses and a shield with the proper filter and cover plates to protect your eyes from
sparks and the rays of the arc when performing or
observing plasma arc cutting or gouging.
Glasses,headshield and filter lens should conform
to ANSI Z87. I standards.
2.b. Use suitable clothing including gloves made from durable
flame-resistant material to protect your skin and that of your
helpers from the arc rays.
2.c. Protect other nearby personnel with suitable non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
to keep fumes and gases away from the breathing zone.
When cutting or gouging on lead or cadmium plated
steel and other metals or coatings which produce highly
toxic fumes keep exposure as low as possible and
below Threshold Limit Values (TLV) using local exhaust
or mechanical ventilation. In confined spaces or in some
circumstances, outdoors, a respirator may be required.
Additional precautions are also required when welding
on galvanized steel.
3.b. Do not use plasma arc cutting or gouging in locations near
chlorinated hydrocarbon vapors coming from degreasing,
cleaning or spraying operations. The heat and rays of the arc
can react with solvent vapors to form phosgene, a highly
toxic gas, and other irritating products.
3.c. Gases used for plasma cutting and gouging can displace air
and cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
3.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your employer’s safety practices.
sparks and hot materials from plasma cutting or gouging can
easily go through small cracks and openings to adjacent
areas. Avoid cutting or gouging near hydraulic lines. Have a
fire extinguisher readily available.
4.b. Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the equipment being used.
4.c. When not cutting or gouging, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard.
4.d. Do not cut or gouge tanks, drums or containers until the proper steps have been taken to insure that such procedures will
not cause flammable or toxic vapors from substances inside.
They can cause an explosion even though they have been
“cleaned.” For information purchase “Recommended Safe
Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
4.e. Vent hollow castings or containers before heating, cutting or
gouging. They may explode.
4.f. Do nor fuel engine driven equipment near area where plasma
cutting or gouging.
FUMES AND GASES
can be dangerous.
3.a. Plasma cutting or gouging may produce
fumes and gases hazardous to health. Avoid
breathing these fumes and gases.When cutting
or gouging, keep your head out of the fumes.
Use enough ventilation and/or exhaust at the arc
CUTTING SPARKS can
cause fire or explosion.
4.a..Remove fire hazards from the plasma cutting or gouging area. If this is not possible, cover
them to prevent the cutting or gouging sparks
from starting a fire. Remember that welding
Apr. ‘93
ii
SAFETY
ii
4.g. Sparks and spatter are thrown from the plasma arc. Wear
safety glasses, ear protection and oil free protective garments
such as leather gloves, heavy shirt, cuffless trousers, high
shoes and a cap over your hair. Wear ear plugs when cutting
or gouging out of position or in confined places. Always wear
safety glasses with side shields when in a cutting or gouging
area.
4.h. Connect the work cable to the work as close to the cutting or
gouging area as practical. Work cables connected to the building framework or other locations away from the cutting or
gouging area increase the possibility of the current passing
through lifting chains, crane cables or other alternate circuits.
This can create fire hazards or overheat lifting chains or
cables until they fail.
CYLINDER may explode
if damaged.
5.a. Use only compressed gas cylinders containing the correct gas for the process used and
properly operating regulators designed for the
gas and pressure used. All hoses, fittings, etc.
should be suitable for the application and maintained in good
condition.
5.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
5.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from plasma cutting or gouging, arc weld-
ing operations and any other source of heat, sparks,
or flame.
5.d. Never allow any part of the electrode, torch or any other
electrically “hot” parts to touch a cylinder.
5.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
5.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
5.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,”available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
FOR ELECTRICALLY
powered equipment.
6.a. Turn off input power using the disconnect
switch at the fuse box before working on the
equipment.
6.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s recommendations.
6.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
PLASMA ARC can injure.
7.a. Keep your body away from nozzle and
plasma arc.
7.b. Operate the pilot arc with caution. The pilot arc is capable of
burning the operator, others or even piercing safety clothing.
ELECTRIC AND MAGNETIC FIELDS
may be dangerous
8.a. Electric current flowing through any conductor causes localized Electric and Magnetic
Fields (EMF). Cutting or gouging current creates EMF fields around torch cables and cutting
machines.
8.b. EMF fields may interfere with some pacemakers, so operators having a pacemaker should consult their physician
before cutting or gouging.
8.c. Exposure to EMF fields during cutting or gouging may have
other health effects which are now not known.
8d. All operators should use the following procedures in order to
minimize exposure to EMF fields from the cutting or gouging
circuit:
8.d.1. Route the torch and work cables together - Secure
them with tape when possible.
8.d.2. Never coil the torch cable around your body.
8.d.3. Do not place your body between the torch and
work cables. If the torch cable is on your right side,
the work cable should also be on your right side.
8.d.4. Connect the work cable to the workpiece as close as
possible to the area being cut or gouged.
8.d.5. Do not work next to cutting power source.
Apr. ‘93
NOTES
iv
SAFETY
iv
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suivantes:
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
d. Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on place
la masse sur la charpente de la construction ou d’autres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer
des risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
du corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
Mar. ‘93
for selecting a QUALITY product by Lincoln Electric. We want you
Thank You
to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
vv
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line Product Registration
- Register your machine with Lincoln Electric either via fax or over the Internet.
• For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.
• For On-Line Registration: Go to our
“Product Registration”. Please complete the form and submit your registration.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
vi
TABLE OF CONTENTS
Page
Installation .......................................................................................................Section A
Parts List .....................................................................................P309 Series & P210-K
TABLE OF CONTENTS
Page
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS - PRO-CUT 55
INPUT
THREE PHASESINGLE PHASE
StandardInput Current
Voltageat Rated OutputModel
208/230/46031/28/1750/60 Hz
200/380-415 30/17/1650/60 Hz
460/57517/1450/60 Hz
StandardInput Current
Voltageat Rated OutputModel
208/230/46060/55/3050/60Hz
RATED OUTPUT
Duty Cycle
AMPS
A-1
VOLTS
50% Duty Cycle
100% Duty Cycle
Current
Range
25-60 Amps
REQUIRED GAS FLOW RATEREQUIRED 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 PHASESINGLE PHASE
Type 75°C
Type 75°CCopper
FuseCopperGround
(Superlag)Wire inWire in
InputorConduitConduit
VoltageBreakerAWG (IEC)AWG (IEC)
Frequency
(1)
SizeSizesSizes
55
40
OUTPUT
Open Circuit
Voltage
MAX
335 VDC
InputorConduitConduit
VoltageBreakerAWG (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°CCopper
FuseCopperGround
(Superlag)Wire inWire in
(1)
SizeSizesSizes
Type 75°C
208/50/604010 (6mm2)10 (6mm2)
230/50/604010(6mm2)10 (6mm2)
460/50/603010 (6mm
200/50/604010 (6mm2)10 (6mm2)
380-415/50/603010 (6mm2)10 (6mm2)
460/50/603010 (6mm
575/50/603010 (6mm2)10 (6mm2)
2
)10 (6mm2)
2
)10 (6mm2)
PHYSICAL DIMENSIONS
idth
Height
12.6 in.
320 mm
(1) Input voltage must be within ±10% of rated value.
W
11.0 in.
280 mm
208/50/60808 (8.4mm2)8 (8.4mm2)
230/50/60808 (8.4mm2)8 (8.4mm2)
460/50/604010 (6mm
2
)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-
DO
riage, if installed, to lift the machine. This handle is not
designed to support the full weight of the machine and
using it to lift the machine could cause personal injury
or damage to the machine.
TILTING
The PRO-CUT 55 must be placed on a stable, level
surface so it will not topple over.
HIGH FREQUENCY INTERFERENCE
PROTECTION
The Pro-Cut 55 employs a touch start mechanism for
arc initiation which eliminates high frequency emissions from the machine as compared with spark gap
and solid state type high frequency generators. Keep
in mind, though, that these machines may be used in
an environment where other high frequency generating machines are operating. By taking the following
steps, high frequency interference into the Pro-Cut
can be minimized
SELECT PROPER LOCATION
Place the Pro-Cut 55 where clean cool air can freely
circulate in through the rear louvers and out through
the front/bottom opening. Dirt, dust or any foreign
material that can be drawn into the machine should be
kept at a minimum. Failure to observe these precautions can result in excessive operating temperatures
and nuisance shutdown of the machine.
A source of clean, dry air or nitrogen must be supplied
to the Pro-Cut 55. Oil in the air is a severe problem
and must be avoided. The supply pressure must be
between 80 and 150 psi. The flow rate is approximately 6.0 cfm (170 l/min.). Failure to observe these precautions could result in excessive operating temperatures or damage to the torch.
STACKING
The PRO-CUT 55 cannot be stacked.
(1) Make sure the power supply chassis is connected
to a good earth ground. The work terminal ground
does NOT ground the machine frame.
(2) Keep the work ground clamp isolated from other
work clamps that have high frequency.
(3) If the ground clamp cannot be isolated, then keep
the clamp as far as possible from other work
clamp connections.
(4) When the machine is enclosed in a metal building,
several good earth driven electrical grounds
around the periphery of the building are recommended.
Failure to observe these recommended installation
procedures may cause improper function of the ProCut or possibly even damage to the control system or
power supply components.
PRO-CUT 55
A-3
INSTALLATION
A-3
INPUT ELECTRICAL
CONNECTIONS
Before installing the machine, check that input supply
voltage, phase, and frequency are the same as the
machine's voltage, phase, and frequency as specified
on the machine's rating plate.
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 DriveAuxiliary Power Pro-Cut 55 Output Cut Thickness
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
80
60
40
20
0
0.0000.1250.250
0.3750.5000.6250.750
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
00
VERVERTICAL ANGLETICAL ANGLE
FOR CUTTINGFOR CUTTING
CUT
90
0
TORCH AT 300ANGLE
TO PIERCE
ROTATE TO
90
0
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.
0
angle away from the opera-
PRO-CUT 55
B-5
E
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
0
ANGLE
45
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
45
DRAG thru 1/16"
Standoff
Output Setting
Min. Range thru 45 Amps
Machine Output Setting
Torch Standoff
45
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
L
C
D=344
E
Arc Voltage
14-PIN BOX RECEPTACLE, FRONT VIEW
J=347
I=348
H
N
G=343
F
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.
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.
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.
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.
1.
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).
3.
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.
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.
J4
365
N.A.
J30
H1
H3
FAN
51
54
56
53
NOTES:
+15V
READY LED
277B
18V18V
J2
7,8 ELEC SHUNT (TWIST PR)
N
4,5 XFER SHUNT (TWIST PR)
G
RIGHT SIDE OF MACHINE
J5
8
PER
N.A.
306
303
302
309
230VAC
A
X4
203A
N.C.
S
E
E
MOTORS
W
401
X2
FAN
OUTPUT
PC BOARD
FAN
361
361
364
360
404
369
366
2
401
4
B21
L1
CHOKE
J40
J3
J40
AIR
11
S5
12
SOLENOID
13
PRESSURE
CONTROL
215
210
214
219
213
218
212
1
4
277A
306
9
14
15
6
16
7
8
503
209
205
501
RELAY
505
208
502
++VOLT
506
P_XFMR
507
J10
201
204
207A
202A
+
2
344
3
2
9
4
309
1
8
5
303
5
6
10
312
4
7
9
3
N
1
8
N
4
G
2
7
2
5
1
3
6
6
OUTPUT
1,4=24V
13 IGBT
14
13
12
11
10
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
9
1
A
S
502
S
H3
S
H3
H2
S
FR-IN
S
8
Y
Y
CURRENT
C2
1200/450
TRANSFORMER
R
W
X4
1
3
R
2
4
2
4
1
3
404
Y
H4
7
201
H3
251
8-18-2000F
LOW_PSI LED
POT WIPER
RESET
GND
THERMAL LED
RESET LED
PSI SET
18V
6
3
H2
XFER
XFER
REAR OF MACHINE
xxxxxxx
205
FR-OUT
FR-IN
S
W
310
3
344
4
5
6
7
8
8
9
7
10
6
5
10
4
9
5
3
8
2
2
7
4
1
3
6
X1
505
501
506
4
507
J2,J21,
J31
208
204
H5
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
12
3
4
13
4
6
1
5
4
1
8
7
6
12
15
5
10
1
6
8
1
16
1
9
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
J3
B
R
E
A
R
O
F
M
A
C
H
I
N
E
J2,J21,
J30,J37
1
2
J39
8
2
5
503
213
506
214
502
218
H1
215
210
Y
16815
7
302
14
6
W
9
312
H1
H3
231
202
X4
201
201A
460VAC
231A
507
I
506
505
B
U
R
S1
V
W
POWER
W
54
53
8
12V
R
N
56
R
N
51
2
24V
J40
11
12
215
210
214
219
213
218
4
277A
306
212
248
217
216
E
N
H2
3
209
J10
501
A
306
X4
303
302
CONTROL
309
N.C.
360
1200/450
440-
460V
OUTPUT
+
-
6
R
W
501
S
B
K
-
O
U
T
S
B
K
-
I
N
219
DISPLAY
WORK
364
369
2
2W
10K
4
CW (MAX)
277
276
R1
R
W
Y
366
361
J20
1
2
+
-
ELEC
XFER
XFER
IN_SENSE
ELEC
J11
502
11
4
5
5
6
8
123
123
9 AIR SOL
TSTAT
10 ELEC SOL
P_XFMR
++VOLT
RELAY
4
10
321
12
13
2,6 PSI SWITCH
5
11 TRIGGER
CT
12 GND
3 IGBT
J3
B
J1
B
K-
OUT
64
61
62
18V
LOW_PSI LED
POT WIPER
RESET
GND
THERMAL LED
SAFETY LED
PSI SET
14
21713212
H6
2
H5
1
3
H4
275
H3
507
J21
T2
AUXILIARY
TRANSFORMER
U64
62
W
61
U
TP3
9
H1
TP2
TP1
H1
B
A
C
D1
INPUT
BRIDGE
209
4
5
1
F
R
O
N
T
O
F
M
A
C
H
I
N
E
365
J4
N.A.
PER
INPUT
221
223
221
}
275
276
277
1
1
2
241A
241A
+15V
READY LED
277B
18V18V
J2
7,8 ELEC SHUNT (TWIST PR)
N
4,5 XFER SHUNT (TWIST PR)
X40
0.6A
RELAY
P_XFMR
++VOLT
RESET
15
SOLENOID
216
223
S3
PSI_SET
277A
4
E
MOTORS
W
401
X2
FAN
FAN
404
401
B21
L1
CHOKE
SLOW BLOW
R
8
1
7
2
6
5
4
550-
575V
H6
H5
W
3
4
5
10
B
K
-I
N
S
RIGHT SIDE OF MACHINE
440-
207A
2
Y
C1
S
S
FR-O
U
T
1200/450
S
S
354
310
N
N
205
X20
X40
9
3
248A
241
201
201A
231
FAN
404
2
4
3
503
3
2
5
1
4
204
241
xxxxxxx
205
204
D
+
A
J5
575VAC
241
-
F
550-
S4 PRIMARY
RECONNECT
J33
208
18V
6
G
S2
xxxxxxx
FR-
O
U
T
FR-
I
N
S
505
CONTROL
S5
X1
PRESSURE
AIR
C2
R
A
206
202
6
POWER
T3
I
R
Y
Y
208
238
S
1
248
T1
MAIN
XFMR
X2
X20
X30
X3
W
X10
TRANSFORMER
CURRENT
6
2
7
3
207A
7
10
9
4
8
7
6
J22
543
POT
1
6
2
4
7
3
8
W
4
9
FR-IN
A
B
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
53
369
56
366
361
2
4
348
347
51
54
G
E
6
1
7
283
9
4
10
5
5
1
309
4
6
2
3
2
1
7
514
6
2
3
8
7
6
172
8
3
9
4
10
5
5
1
344
4
6
2
3
360
343
365
10
11
12
8
9
1,7 TRIGGER
3,4 AIR SOL
5,6 ELEC SOL
1 NOZZLE
J38
5, 10 ELECTRODE
3,8 WORK
11,12 = 12V
OUTPUT
L1
401
E
S
J35
J37
xxxxxxx
53
56
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.
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.
J4
365
N.A.
J35
H1
H3
FAN
NOTES:
+15V
READY LED
277B
18V18V
J2
7,8 ELEC SHUNT (TWIST PR)
N
4,5 XFER SHUNT (TWIST PR)
G
RIGHT SIDE OF MACHINE
J5
PER
N.A.
306
303
302
309
230VAC
A
X4
203A
N.C.
S
E
MOTORS
W
401
X2
FAN
OUTPUT
PC BOARD
FAN
404
401
B21
L1
CHOKE
J40
J3
J40
AIR
11
S5
12
SOLENOID
13
PRESSURE
CONTROL
215
210
214
219
213
218
212
1
4
277A
306
9
14
15
6167
8
503
209
205
501
RELAY
505
208
502
++VOLT
506
P_XFMR
507
J10
201
204
207A
202A
-
+
2
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
9
1
A
S
502
S
H3
S
H3
H2
S
FR-IN
S
8
Y
Y
CURRENT
C2
1200/450
TRANSFORMER
R
W
X4
1
3
R
2
4
2
4
1
3
404
Y
H4
7
201
H3
251
}
B
LOW_PSI LED
POT WIPER
RESET
GND
THERMAL LED
SAFETY LED
PSI SET
18V
6
3
H2
XFER
XFER
R
E
A
R
O
F
M
A
C
H
I
N
E
xxxxxxx
205
FR-O
U
T
FR-IN
S
W
310
3
354
4
5
6
7
8
8
9
7
10
6
5
10
4
9
5
3
8
2
2
7
4
1
3
6
X1
505
501
506
4
507
J2,J21,
J37,J39
208
204
H5
1
2
J39
211
RESET LED
8
211
A
A
9
8
12
11
10
365
343
360
3
2
6
4
344
1
5
5
10
4
9
3
8
2716
7
8
3
2
6
415
7
1
2
3
2
6
4
309
1
5
5
10
4
9
382
7
1
6
E
G
54
51
347
348
4
2
361
366
56
369
53
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
53
56
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
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.