Lincoln Electric IM944 User Manual
IM944
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POWERTORCH™ PLASMA 20
For use with machines having Code Number:
Safety Depends on You
Harris 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 op eration on you r part. DO
NOT IN ST AL L, OPERATE OR
REP AIR THI S E QUIP MENT
WIT HOUT REA DING THI S
MAN UAL A ND T HE S A FET Y
PRECAU TIO NS CON TAI NED
THR OUGH OUT. And , mo st
importantly, think before you act
and be careful.
December, 2008
11453
OPERATOR’S MANUAL
Copyright © Lincoln Global Inc.
Gainesville, GA 30504-6000 U.S.A. TEL: 866.236.0044 FAX: 800.840.8684
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.
to keep fumes and gases away from the breathing zone.
When plasma 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
plasma cutting or gouging on galvanized steel.
3. b. The operation of plasma cutting or gouging fume control
equipment is affected by various factors including proper
use and positioning of the equipment, maintenance of the
equipmen t and the specifi c procedure and a pplicati on
involved. Worker exposure level should be checked upon
installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits.
3.c. Do not use plasma cutting or gouging equipment 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.d. 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.e. Read and understand the manufacturerʼs instructions for this
equipment and follow your employerʼs safety practices.
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
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
ob s er v in g pl a sm a ar c cu t ti n g o r go ugi ng.
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.
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 s tarting a fire . Reme mber that weld ing
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 situati on s. Refer to “Safety in Wel di ng and Cu tt ing” (ANSI
Standard Z49.1) and the operating information for the equipment being used.
Aug. ʻ06
ii
SAFETY
ii
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
ca n c aus e a n e xpl os i on eve n t hou gh th ey hav e b een
“cleaned.” For information purchase “Recommended Safe
Pract ices for the Prepa ratio n f or We lding and Cutti ng of
Co n ta i ne r s a n d P ipi ng T hat H ave Hel d Ha zar dou s
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.
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 f ire hazards or overheat lifting chains or
cables until they fail.
4.I. Read and follow NFPA 51B “ Standard for Prevention During
Welding, Cutting and Other Hot Work”, available from NFPA, 1
Batterymarch Park,PO box 9101, Quincy, Ma 022690-9101.
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. Alway s k eep cyli nders in an upri ght posi tion secur ely
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, associa ted 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 manufacturerʼs recommendations.
6.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturerʼs 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.
Jan., 07
iii
SAFETY
iii
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suivantes:
Sûreté Pour Soudage A LʼArc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à lʼélectrode 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 sʼisoler 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 lʼeau 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 sʼapplicuent aussi au pistolet de
soudage.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque dʼincendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-c ircuit accidental peut provo quer un
échauffement et un risque dʼincendie.
8. Sʼassurer que la masse est connectée le plus prés possible
de la zone de travail quʼil est pratique de le faire. Si on place
la masse sur la charpente de la construction ou dʼautres
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 dʼincendie ou dʼechauffement des chaines et des
câbles jusquʼà ce quʼils 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
dʼo pérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de lʼarc 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 nʼimporte quelle partie
du corps.
3. Un coup dʼarc peut être plus sévère quʼun coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi quʼun verre blanc afin de se protéger les yeux du rayonnement de lʼarc et des projections quand on soude ou
quand on regarde lʼarc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
lʻarc.
c. Pr otéger lʼautre personn el tr availla nt à proxi mité au
soudage à lʼaide dʼécrans appropriés et non-inflammables.
4. De s gouttes de laiti er en fusion sont émises de lʼarc de
soudage. Se protéger avec des vêtements de protection libres
de lʼhuile, 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 lʼon 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
lʼélectricité 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, Iʼinstallation et lʼentretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à lʼinterieur de poste, la debrancher à lʼinterrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
Mar. ʻ93
iv
for selecting one of our QUALITY products. We want you to take
TThhaannkk YYoouu
CUSTOMER ASSISTANCE POLICY
The business of our company is manufacturing and selling high quality welding equipment. Our challenge is to
meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask us for
advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. We are not in a position to warrant or guarantee such advice, and assume no
liability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including any
warranty of fitness for any customerʼs particular purpose, with respect to such information or advice. As a matter
of practical consideration, we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any
warranty with respect to the sale of our products.
We are a responsive manufacturer, but the selection and use of specific products sold by us is solely within the
control of, and remains the sole responsibility of the customer. Many variables beyond our control affect the
results obtained in applying these types of fabrication methods and service requirements.
Subject to Change – This information is accurate to the best of our knowledge at the time of printing.
pride in operating this 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.
iv
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 (if available)______________________________________________________
Serial Number (if available)__________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
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.
v
v
TABLE OF CONTENTS
Page
Installation.......................................................................................................................Section A
Technical Specifications.......................................................................................................A-1
Safety Precautions ...............................................................................................................A-2
Select Proper Location .........................................................................................................A-2
Stacking................................................................................................................................A-2
Tilting....................................................................................................................................A-2
High Frequency Interference Protection...............................................................................A-2
Input Electrical Connections.................................................................................................A-2
Compressed Air or Gas Input Connections..........................................................................A-3
Connections to Ground Cable ..............................................................................................A-3
Torch Connections ...............................................................................................................A-3
________________________________________________________________________________
Operation.........................................................................................................................Section B
Safety Precautions ...............................................................................................................B-1
Description ...........................................................................................................................B-1
User Responsibility...............................................................................................................B-2
Design Features and Advantages ........................................................................................B-2
Cutting Capability .................................................................................................................B-2
Torch Consumables ............................................................................................................B-2
Limitations ............................................................................................................................B-2
Controls and Settings ...........................................................................................................B-2
Cutting Operations ...............................................................................................................B-3
Check Air Quality..................................................................................................................B-3
Cutting with a Hand Torch ............................................................................................B-3, B-4
Pilot Arc Discussion..............................................................................................................B-5
Torch Consumable Parts Selection......................................................................................B-6
________________________________________________________________________
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
Routine Maintenance.............................................................................................D-1
Periodic Maintenance............................................................................................D-1
Compressed Air Filter............................................................................................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
––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––
Parts Lists...................................................................................................P-564 Series
________________________________________________________________________
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS - POWERTORCH™ PLASMA 20 (K2682-1)
INPUT - SINGLE PHASE
Standard Voltage
115/1/50/60Hz (15 Amp Branch)
115/1/50/60Hz (20 Amp Branch with 20 Amp Plug*)
1Ø Input Current at Rated Output
115 V: 20A @ 50%
115 V: 26A @ 40%
RATED OUTPUT
Duty Cycle
AMPS
A-1
50% on 115V (15 Amp Branch)
40% on 115V (20 Amp Branch with 20 Amp Plug*)
OUTPUT
Current
Range
10-20 Amps
Open Circuit
REQUIRED AIR FLOW RATE REQUIRED AIR INLET PRESSURE
3.5 cu. ft./min.
(100L/min.)
RECOMMEND INPUT WIRE AND FUSE SIZES
For all plasma cutting applications
Based on U.S. National Electrical Code
Ambient Temperature 30
Output
AC Input
Voltage
at
50/60
Hertz
Plug Size
Circuit Breaker
or Fuse Size
Voltage
310 VDC
Maximum
Time-Delay
o
C or Less
15 A
20 A
Pilot Current
17 Amps
72.5 to 150 PSI
( 5 Bar TO 10.3 Bar)
Type SJT or Hard Usage
Input Cord
20 A
15 A
115V-1Ø
115V-1Ø
5-20P*
5-15P
20 Amps
15 Amps
PHYSICAL DIMENSIONS
Height
12 in.
305 mm
*5-20P plug must comply with the standard for attachment plugs and receptacles, UL498.
Width
6 in.
152 mm
POWERTORCH™ PLASMA 20
Depth
16 in.
406 mm
3 Conductor, #14 AWG
Weight
Including
Torch Cable
21 lbs.
9.5 kg.
A-2
Read entire Installation Section before installing the
POWERTORCH™ PLASMA 20.
INSTALLATION
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK CAN KILL.
• Only qualified personnel should perform this installation.
• Only personnel that have read and
understood the POWERTORCH™ PLASMA 20 Operating Manual should install
and operate this equipment.
• Machine must be plugged into a receptacle which is
grounded per any national, local or other applicable
electrical codes.
• The POWERTORCH™ PLASMA 20 power switch is to
be in the OFF (“O”) position when installing work
cable, torch parts and when connecting power cord to
input power.
___________________________________________
SELECT PROPER LOCATION
A-2
(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 clamp isolated from other work
clamps that have high frequency.
(3) If the work 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 goo d earth dri ven electrical grounds
around the periphery of the building are recommended.
Failure to observe these recommended installation
procedures may cause improper function of the POWERTORCH™ PLASMA 20 or possibly even damage
to the control system or power supply components.
INPUT ELECTRICAL CONNECTIONS
The POWERTORCH™ PLASMA 20 must be connected to a Line-Neutral system with protective grounding
wire. Check that the relevant electrical outlet is actually connected to the distribution system grounding.
Pl ace the POWERTORC H™ PLASMA 20 where
clean cool air can freely circulate in and out the front,
rear and side louvers. Dirt, dust, smoke, gas or any
foreign material that can be drawn into the machine
should be kept at a minimum. Insure open space of at
least 15 ft. around the machine. Failure to observe
these precautions can result in excessive operating
temperatures and nuisance shutdown of the machine.
STACKING
The POWERTORCH™ PLASMA 20 cannot be
stacked.
TILTING
The POWERTORCH™ PLASMA 20 must be placed
on a stable, level surface so it will not topple over.
HIGH FREQUENCY INTERFERENCE
PROTECTION
The POWERTORCH™ PLASMA 20 employs a touch
start mechanism for arc initiation which eliminates
high frequency emissions from the machine as compared with spark gap and solid state type high frequency generators. Keep in mind, though, that these
machines may be used in an environment where other
high frequency generating machines are operating.
By taking the following steps, high frequency interference into the POWERTORCH™ can be minimized.
The P OWE RTOR CH™ PL ASM A 20 is rat ed for
115VAC input.
Use on 15 amp branch circuits will limit cutting output.
When the output is set at 16 amps or greater, the
input fuse or circuit breaker may “blow” in roughly 30
seconds or less (depending on fuse or circuit breaker
type).
To achieve 16-20 amp output with 115VAC input,
replace the 15 amp plug on the input cord with a 20
amp plug, and connect the unit to a 20 amp branch
circuit with super lag fuses (or equivalent breaker). To
install 20 amp plug: Connect the white (neutral) wire
under terminal clamp with silver screw, and black (hot)
wire under terminal clamp with brass screw. Connect
green wire under terminal clamp with green screw.
Tighten terminal wire clamp screws securely.
5-20P plug must comply with the standard for attachment plugs and receptacles, UL498. This product is
acceptable for use only when an attachment plug as
specified is properly attached to the supply cord.
WARNING
• Failure to wire as instructed may cause personal
injury or damage to equipment.
• To be installed or checked by an electrician or
qualified person only.
------------------------------------------------------------------------
POWERTORCH™ PLASMA 20
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