Lincoln Electric PRO-CUT 60 User Manual
PPRROO--CCUUTT 6600
((SSiinnggllee PPhhaassee))
SERVICE MANUAL
For use with machines having Code Numbers:
9819, 10096, 10112
10118, 10217, 10218
10393, 10394
SVM104-A
March, 1999
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thoughtful
operation on your part. DO NOT
INSTALL, OPERATE OR REPAIR
THIS EQUIPMENT WITHOUT
READING THIS MANUAL AND
THE SAFETY PRECAUTIONS
CONTAINED THROUGHOUT.
And, most importantly, think before
you act and be careful.
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• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors
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SAFETY
i
WARNING
CUTTING 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 W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the
Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
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 welder or cutter
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. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
In addition to the normal safety precautions, if welding or
cutting must be performed under electrically
hazardous conditions (in damp locations or while
wearing wet clothing; on metal structures such as
floors, gratings or scaffolds; when in cramped positions
such as sitting, kneeling or lying, if there is a high risk
of unavoidable or accidental contact with the workpiece
or ground) use the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
1.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
1.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
1.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
2.b. Use suitable clothing 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.
ting with electrodes which require special ventilation such as
stainless or hard facing (see instructions on container or
MSDS) or 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.
ARC RAYS can burn.
2.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or cutting or
observing open arc welding or cutting.
Headshield and filter lens should conform to
ANSI Z87. I standards.
FUMES AND GASES
can be dangerous.
3.a.Welding or cutting may produce fumes and
gases hazardous to health. Avoid breathing
these fumes and gases.When welding,
or cutting keep your head out of the fume.
Use enough
arc to keep
breathing zone. When welding or cut-
ventilation and/or exhaust at the
fumes and gases away from the
1.f.
Maintain the electrode holder, work clamp, welding or cutting
cable and
condition. Replace
1.g. Never dip the electrode in water for cooling.
1.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
1.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
1.j. Also see Items 4.c. and 6.
welding or cutting machine in good, safe operating
damaged insulation.
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3.b.
Do not weld or cut 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 toform phosgene, a highly toxic gas, and
other irritating products.
3.c. Shielding gases used for arc welding or cutting 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. MSDS forms are available from
your welding distributor or from the manufacturer.
3.e. Also see item 7b.
PRO-CUT 60
SAFETY ii
WELDING OR CUTTING
SPARKS can cause fire or
explosion.
4.a.
Remove fire hazards from the welding or cutting area.
prevent the welding or cutting sparks from start-
ing a fire. Remember that welding or cutting sparks and hot
materials from welding or cutting can easily go through small
cracks and openings to adjacent areas. Avoid welding or cutting 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 welding or cutting, 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 heat, cut or weld 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
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
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
welding. They may explode.
If this is not possible, cover them to
though
they have
Preparation
for Welding and Cutting of
CYLINDER may explode
if damaged.
5.a. Use only compressed gas cylinders
containing the correct shielding 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 arc welding or cutting operations and
any other source of heat, sparks, or flame.
5.d. Never allow the electrode, electrode holder 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.
4.f.
Sparks and spatter are thrown from the welding and cutting
arc. Wear oil
heavy shirt, cuffless trousers, high shoes and a cap over
your hair. Wear ear plugs when welding or cutting out of position or in confined places. Always wear safety glasses with
side shields when in a welding or cutting area.
4.g. Connect the work cable to the work as close to the welding
or cutting area as practical. Work cables connected to the
building framework or other locations away from the welding
area increase the possibility of the welding or cutting 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.
4.h. Also see item 7c.
free protective garments such as leather gloves,
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.
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PRO-CUT 60
SAFETY iii
FOR ENGINE
powered equipment.
7.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
7.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
____________________________________________________
7.c. Do not add the fuel near an open flame
welding or cutting arc or when the engine is
running. Stop the engine and allow it to cool
before refueling to prevent spilled fuel from
vaporizing on contact with hot engine parts
and igniting. Do not spill fuel when filling
tank. If fuel is spilled, wipe it up and do not
start engine until fumes have been
eliminated.
____________________________________________________
7.d. Keep all equipment safety guards, covers
and devices in position and in good repair.
Keep hands, hair, clothing and tools away
from V-belts, gears, fans and all other
moving parts when starting, operating or
repairing equipment.
ELECTRIC AND MAGNETIC
FIELDS
may be dangerous
8.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding or
cutting current creates EMF fields around welding or
cutting cables and welding machines
8.b. EMF fields may interfere with some pacemakers, and
welders or cutters having a pacemaker should consult their
physician before welding or cutting.
8.c. Exposure to EMF fields in welding or cutting may have other
health effects which are now not known.
8d. All welders or cutters should use the following procedures in
order to minimize exposure to EMF fields from the welding
or cutting circuit:
8.d.1.
Route the electrode and work cables together - Secure
them with tape when possible.
8.d.2. Never coil the electrode lead around your body.
8.d.3. Do not place your body between the electrode and
work cables. If the electrode 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 welded.
8.d.5. Do not work next to welding or cutting power source.
____________________________________________________
7.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
7.f. Do not put your hands near the engine fan. Do not
attempt to override the governor or idler by pushing on
the throttle control rods while the engine is running.
7.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
___________________________________________________
7.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
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PRO-CUT 60
SAFETY iv
PRÉCAUTIONS DE SÛRETÉ
Pour
votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suivantes:
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble de
soudage et la machine à souder en bon et sûr état defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
zones où l’on pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible de
la zone de travail qu’il est pratique de le faire. Si on place la
masse sur la charpente de la construction ou d’autres endroits
éloignés de la zone de travail, on augmente le risque de voir
passer le courant de soudage par les chaines de levage,
câbles de grue, ou autres circuits. Cela peut provoquer des
risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté, voir
le code “Code for safety in welding and cutting” CSAStandard
W 117.2-1974.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
du corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
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PRO-CUT 60
RETURN TO MAIN INDEX
MASTER TABLE OF CONTENTS FOR ALL SECTIONS
Page
Safety ................................................................................................................................iv
Installation ..........................................................................................................Section A
Technical Specifications .......................................................................................... A-1
Safety Precautions .................................................................................................. A-2
Select Proper Location .............................................................................................A-2
High Frequency Interference Protection...................................................................A-2
Input Electrical Connections ................................................................................... A-3
Reconnect Procedure ............................................................................................. A-6
Output Connections ................................................................................................ A-7
Operation ............................................................................................................Section B
Operating Instructions ............................................................................................ B-1
Safety Precautions ................................................................................................. B-1
General Description ................................................................................................ B-2
Recommended Processes and Equipment..............................................................B-2
Operational Features and Controls .........................................................................B-2
Design Features and Advantages ...........................................................................B-2
Cutting and Gouging Capability .............................................................................. B-3
Limitations ................................................................................................................B-3
Controls and Settings ..............................................................................................B-3
Operating Steps ...................................................................................................... B-4
Cutting Procedure Recommendations .................................................................... B-5
v
Accessories........................................................................................................Section C
Accessories ..............................................................................................................C-1
Maintenance........................................................................................................Section D
Safety Precautions ...................................................................................................D-1
Routine and Periodic Maintenance ..........................................................................D-1
3-D Exploded View...................................................................................................D-2
Theory of Operation...........................................................................................Section E
Power Supply Operation..................................................................................E1 – E-5
SCR Operation .........................................................................................................E-6
Thermal Protection ...................................................................................................E-7
Troubleshooting and Repair..............................................................................Section F
How To Use Troubleshooting Guide.........................................................................F-1
PC Board Troubleshooting Procedures....................................................................F-2
Troubleshooting Guide..................................................................................F-3 – F-52
Electrical Diagrams............................................................................................Section G
Parts Manual .............................................................................................................P-184
PRO-CUT 60
TABLE OF CONTENTS
Section A
- INSTALLATION SECTION -
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-3
Fuses and Wire Sizes..............................................................................................A-4
Ground Connection ................................................................................................ A-4
Input Power Supply Connections .............................................................................A-4
Air Input Connections...............................................................................................A-5
Reconnect Procedure ................................................................................................... A-6
Output Connections ...................................................................................................... A-7
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PRO-CUT 60
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS - PRO-CUT 60
INPUT - SINGLE PHASE / 60 HERTZ ONLY
Standard Voltage
208/230/460
460/575
Duty Cycle
60% Duty Cycle
100% Duty Cycle
Current
Range
25-60 Amps
Input Current at
Rated Output
50/45/23
23/18
RATED OUTPUT
AMPS
60
45
OUTPUT
Open Circuit
Voltage
MIN MAX
235VAC 280 VAC
Codes
10112, 9819
10118, 10096
Volts at Rated Amps
115
115
Pilot Current
22.5A (20 seconds
out of 80
seconds)
AC Input
Voltage at
60 Hertz
208/230
460/575
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Height
34 in.
864 mm
RECOMMEND INPUT WIRE AND FUSE SIZES
For all plasma cutting applications
Based on U.S. National Electrical Code
Ambient Temperature 30oC or Less
Fuse
(Super Lag)
Circuit Breaker
(Delay Type)
50 AMPS
25 AMPS
Type 75
Copper Wire in Conduit AWG (IEC) Sizes
o
C
2 Input Supply Wires 1 Ground Wire
2
#8 (8.4mm
#10 (5.3mm2)
)
PHYSICAL DIMENSIONS
(INCLUDES LIFT BAIL AND UNDERCARRIAGE W/O HANDLE)
Width
19 in.
483 mm
Depth
22 in.
559 mm
Torch Cable (Length)
(25ft/7.6m) (50ft/15.2m)
322 lbs. 329 lbs.
146 kg. 149 kg.
#10 (5.3mm2)
#10 (5.3mm2)
Weight
Including Machine
PRO-CUT 60
INSTALLATION
A-2
Read entire Installation Section before installing
the PRO-CUT 60.
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK CAN KILL.
• Only qualified personnel
should install this machine.
• Turn the input power OFF
at the disconnect switch or
fuse box before working on
the equipment.
• Do not touch electrically hot parts.
• Always connect the PRO-CUT 60 grounding terminal (located on the side of the
Case Back Assembly) to a good electrical
earth ground.
TILTING
The PRO-CUT 60 must be placed on a stable,
level surface using the attached undercarriage so
it will not topple over.
HIGH FREQUENCY INTERFERENCE
PROTECTION
Locating, installing, or maintaining the PRO-CUT
60 incorrectly could cause interference with proper radio, TV, or electronic equipment operation
and result in poor cutting and gouging performance. The spark gap oscillator in the machine's
high frequency generator generates electrical signals like a radio transmitter that can cause high
frequency interference. Therefore, properly locating, installing, and maintaining the machine can
reduce or eliminate the effects of high frequency
interference or the loss of high frequency machine
operating power.
The following procedures should be followed to
minimize interference to the following areas:
• Turn the PRO-CUT Power Switch OFF
when connecting power cord to input
power.
__________________
SELECT PROPER LOCATION
Place the PRO-CUT 60 where clean air can freely
circulate in through the front intake and out
through the rear louvers. Dirt, dust, or any foreign
material that can be drawn into the machine
should be kept at a minimum. Not following these
precautions can result in the nuisance shutdown
of the machine because of excessive operating
temperatures.
The location or improper installation of the
machine could affect the operation of radio, TV, or
electronic equipment. See the HIGH FREQUENCY INTERFERENCE PROTECTION Section for
more information.
STACKING
The PRO-CUT 60 cannot be stacked.
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• the machine
• the cutting leads
• feedback into the power lines
• ungrounded metallic objects
1. Make the power supply lines as short as
possible.
2. Enclose power supply lines entirely in rigid
metallic conduit (or equivalent shielding)
a. Provide a good electrical ground between
the conduit and the machine.
b. Connect both ends of the conduit to a
driven ground.
c. Entire conduit length should be
continuous.
NOTE: The machine frame must be grounded.
The work terminal ground DOES NOT ground
the machine frame.
PRO-CUT 60
A-3
INSTALLATION
3. Connect the work terminal to a ground within
ten feet of the machine.
a. Use grounding cable that is the same size
as, or larger than, the work cable.
b. Make grounding cable as short as
possible.
c. Connect the ground tightly.
d. Use one of the following ground methods:
(1) Connect to a metal underground water
pipe that is in direct contact with earth for
ten feet or more.
(2) Connect to 3/4" (19mm) galvanized pipe
or a 5/8" (16mm) solid galvanized iron,
steel, or copper rod driven at least eight
feet into the ground.
NOTE: Do Not use the building frame electrical conduit or a long pipe system for grounding the machine. This could result in
increased high frequency interference.
NOTE: When the machine is used in a
metal building, drive several good earth
grounds around the edge of the building. Use
the method in 2 above.
a. Use insulated work cables with a high
natural rubber content, such as the Lincoln
Stable-Arc cables. These better resist
high frequency leakage than neoprene or
other synthetic rubber insulated cables.
7. Keep the torch in good repair and all connections tight to reduce high frequency leakage.
8. Keep all access panels and covers tightly
closed.
Follow these procedures for the best operating
results. Failure to follow these procedures can
cause interference and machine performance
problems.
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
on the Case Front Assembly. See Figure A.1 for
the location of the machine's input cable entry
opening, terminal block, and reconnect panel
assembly. Input power supply entry is through the
hole in the Case Back Assembly.
4. Enclose all electrical conductors within 50 feet
(15.2m) of the machine in grounded rigid
metallic conduit or equivalent shielding.
a. Do not use flexible metallic conduit.
5. Make work and torch leads as short and as
close together as possible.
a. Lead length should not exceed 50 feet
b. Tape leads together when possible.
6. Check torch and work cable rubber insulation
coverings to be sure they do not have any
cracks or cuts that could result in high frequency leakage that could interfere with other
electronic equipment.
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(15.2m).
➁
➀
FIGURE A.1 - Case Back Assembly
1. Input Supply Cable Entry Opening
2. Terminal Block
3. Reconnect Panel Assembly
4. Air Pressure Regulator.
➂
➃
PRO-CUT 60
INSTALLATION
A-4
FUSE AND WIRE SIZES
Protect the input circuit with the super lag fuses or
delay type circuit breakers listed on the
Specifications page of this manual for the
machine being used. The tripping action of delay
type circuit breakers decreases as the magnitude
of the current increases. They are also called
inverse time or thermal/magnetic circuit breakers.
DO NOT use fuses or circuit breakers with a lower
amp rating than recommended. This can result in
"nuisance" tripping caused by inrush current even
when machine is not being used for cutting or
gouging at high output currents.
Use input and grounding wire sizes that meet
local electrical codes or see the Specifications
page in this manual.
GROUND CONNECTION
b. For #10 AWG wire (5.3mm), connect leads
to terminal block using the ferrules
(S19117-1)provided.
(1) Strip 1/2" (12.7mm) of insulation from
wire.
(2) Place ferrule over wire.
(3) Connect to machine terminal block.
c. Tighten screws to 16 in/lbs (1.8 N.M.)
Ground the frame of the machine. A ground terminal marked with the symbol ( ) is located at the
left side of the Input Box Assembly. Access to the
Input Box Assembly is at the top-rear of the
machine. See your local and national electrical
codes for proper grounding methods.
INPUT POWER SUPPLY CONNECTIONS
A qualified electrician should connect the input
power supply leads to the L1 and L2 terminals on
the Input Box Assembly Terminal Block.
1. Follow all national and local electrical codes.
2. Follow Input Supply Connection Diagram
located on the inside of the access door.
3. Use a single-phase line or one phase of a
three-phase line.
GND.
L1
L2
TERMINAL
BLOCK
PANEL ASSEMBLY
2
For #10 (5.3mm
AWG Wire Only
Place Ferrule (S19117-1) Over Wire as Shown
Before Insertion into Machine Terminal Block.
.50"
)
(12.7 mm)
Strip #10 (5.3mm
RECONNECT
2
) Wire
4. Connect leads to machine's terminal block.
See Figure A.2.
a. For #8 AWG wire (8.4mm), connect leads
directly to machine's terminal block.
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FIGURE A.2 - Input Power Supply
Connections.
PRO-CUT 60
A-5
INSTALLATION
AIR INPUT CONNECTIONS
Supply the PRO-CUT 60 with clean compressed
air or nitrogen.
WARNING
CYLINDER could explode if damaged.
• Supply pressure must be between 70 psi
and 120 psi (482 kPa and 827 kPa).
• Flow rate should be approximately 4.7
cfm (133 I/min.).
NOTE: Oil in the air supply to the PRO-CUT 60
can cause severe problems. Use only a clean air
supply.
1. Connect the air supply to the PRO-CUT 60
regulator.
a. Remove the plastic thread protector from
the machine's regulator input port located
on the back of the machine. Refer to figure
A.1.
-The input port is a 1/4" (6.3mm) NPT
thread.
b. Connect the air supply to the machine reg-
ulator with an appropriate gas connection
fitting. Sealing the connection with Teflon
tape is recommended.
• 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 120 psi
(827kPa).
__________________
2. Tighten the air fitting connection to prevent
leakage.
-Do not overtighten.
NOTE: When using nitrogen gas from a cylinder,
the cylinder must have a pressure regulator.
• Maximum psi from nitrogen gas cylinder to
• Install a hose between the nitrogen gas
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PRO-CUT 60
PRO-CUT 60 regulator should never
exceed 120 psi (827 kPa).
cylinder regulator and the PRO-CUT 60
regulator's gas inlet.
INSTALLATION
A-6
RECONNECT PROCEDURE
Multiple voltage machines are shipped connected
to the highest input voltage listed on the
machine's rating plate. Before installing the
machine, check that the Reconnect Panel in the
Input Box Assembly is connected for the proper
voltage.
CAUTION
Failure to follow these instructions can cause
immediate failure of components within the
machine.
__________________
To reconnect the machine to a different voltage,
change the position of the power straps (links) on
the reconnect panel assembly. Follow The Input
Supply Connection Diagram located on the inside
of the access door.
1. For 208/230/460 VAC machines, see
Figure A.3a.
460V
GND.
USE FERRULE
#10 AWG ONLY
460 V., 60HZ.
L1
L2
LINK POSITIONS
LINK
230V
GND.
230 V., 60HZ.
L1
L2
LINK POSITIONS
LINK
208V
GND.
208 V., 60HZ.
L1
L2
LINK POSITIONS
LINK
FIGURE A.3a-Voltage Link Positions for
208/230/460 VAC machines.
2. For 460/575 VAC machines, see Figure
A.3b.
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575V
GND.
USE FERRULE
#10 AWG ONLY
575 V., 60HZ.
L1
L2
LINK POSITIONS
LINK
460V
GND.
460 V., 60HZ.
L1
L2
LINK POSITIONS
LINK
FIGURE A.3b - Voltage Link Positions for
460/575 VAC machines.
PRO-CUT 60
A-7
OUTPUT CONNECTIONS
INSTALLATION
WARNING
To avoid receiving a high frequency shock, keep
the torch and cables in good condition.
__________________
The standard PRO-CUT 60 cutting torch comes
with a 25 ft. (7.6m) cable. Acutting torch with a 50
ft. (15.2m) cable is available. The PRO-CUT 60 is
shipped with the torch and work cables already
connected. Should you have to connect the torch
or work cables, use the following procedure:
See Figure A.4 for the location of torch and work
connections.
Connect cutting torch to machine. See Figure
A.4.
➁
➀
➇
➀ Strain Relief Clamp
➁ 4-Pin Connector
➂ Bulkhead Connector
(Brass Fitting)
➃ Gas Line
➂
➃
➄
PILOT
➅
WORK
➆
➄ Pilot Lead
➅ Bolt
➆ Work Lead
➇ Cable Boot
1. Turn OFF Power Line switch.
2. Disconnect input power to the machine.
3. Insert the torch cable into the machine
through the cable boot (8).
a. Insert enough torch cable to make all
connections.
4. Turn and lock strain relief clamp (1) onto bolt
to secure the gas line.
5. Connect the gas line fitting to the brass union
and tighten with a wrench.
6. Connect to pilot lead (5) to terminal marked
“PILOT”.
7. Connect work lead (7) to terminal marked
“WORK”.
FIGURE A.4. -- Connect Torch Cable To
Machine
Connect work clamp to work clamp cable, which
extends from the front of the machine. See Figure
A.5.
1. Insert the cable through the hole at the end of
the work clamp handle.
2. Pull the work clamp cable through the hole
until it reaches the nut and bolt assembly.
3. Tighten the nut and bolt.
8. Connect 4-pin connector (2).
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PRO-CUT 60
FIGURE A.5. -- Connect Work Clamp
TABLE OF CONTENTS
Section B
- OPERATION SECTION -
Page
Operation ...............................................................................................................Section B
Safety Precautions ...................................................................................................... B-1
General Description ..................................................................................................... B-2
Recommended Processes and Equipment...................................................................B-2
Operational Features and Controls ..............................................................................B-2
Design Features and Advantages ................................................................................B-2
Cutting and Gouging Capability .................................................................................. B-3
Limitations ....................................................................................................................B-3
Controls and Settings ...................................................................................................B-3
Operating Steps .......................................................................................................... B-4
Cutting Procedure Recommendations ........................................................................ B-5
Pilot Arc....................................................................................................................B-5
Cutting and Gouging Recommendations.................................................................B-5
Cutting Thin Metal....................................................................................................B-6
Cutting Expanded Metal ..........................................................................................B-7
Cutting Thick Metal..................................................................................................B-7
Gouging Metal .........................................................................................................B-8
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PRO-CUT 60
B-1
OPERATION
SAFETY PRECAUTIONS - Read and understand entire section before operating 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.
ARC RAYS
can burn.
• Wear eye, ear and body
protection.
PLASMA ARC
can injure
• Keep your body away from nozzle
and plasma arc.
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PRO-CUT 60
• 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.
OPERATION
B-2
GENERAL DESCRIPTION
The PRO-CUT 60 is a constant current, single
range, continuous control plasma cutting system.
The microprocessor-based PRO-CUT 60 is capable of cutting with compressed air or nitrogen gas.
Nitrogen gas is used to cut aluminum or other
non-ferrous metals. This sophisticated system has
excellent starting characteristics, cutting visibility,
and arc stability. The machine automatically performs fundamental troubleshooting when turned
ON.
The PRO-CUT 60 is equipped with a patented
plasma torch that has a safety mechanism that
assures consumables are in place before cutting
or gouging. This is extremely important due to
the high voltages involved. Two standard torch
cable lengths are available: a 25 ft. (7.6m) torch
cable or a 50 ft. (15.2m) torch cable. The machine
also comes with an air regulator, coarse air filter,
pressure gage, and spare parts kit. The standard
undercarriage is shipped assembled, except for
the handle.
• Single continuous output range of 25-60
amps.
• Microprocessor controlled overshooting
limiting function increases consumable
life.
• High intensity, high frequency starter.
• Unique microprocessor controlled starting
sequence for consistent starting and torch
protection.
• Solid state pilot duty cycle limiting.Protects
components without fuses that would have
to be replaced.
• Bright 2.5-second timed pilot arc.
• Purge/Run switch.
• Two independent mechanisms for sensing
a shorted torch. Needed for safety and
torch protection.
RECOMMENDED PROCESSES AND
EQUIPMENT
The PRO-CUT 60 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 60 comes with an ON/OFF
POWER SWITCH, OUTPUT CURRENT CONTROL, and a RUN/PURGE SWITCH.
DESIGN FEATURES AND
ADVANTAGES
The microprocessor controlled PRO-CUT 60
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 of your machine.
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• Patented safety sensor monitors if torch
parts are in place.
• Latching safety circuit mechanism requires
that the operator reset the circuit.
• Exposed torch parts voltage monitoring
with safety shutdown.
• Built-in undercarriage for portability.
• Built-in air controls, including air pressure
regulator.
• Air line filtering.
• Preflow/Afterflow timing. Preflow stops if
cutting or gouging resumes in previous
afterflow.
• Easy to use torch trigger switch.
• Line voltage compensated.
• Thermostatically protected.
• Solid state overcurrent protection.
PRO-CUT 60
B-3
OPERATION
• Works with pure nitrogen for cutting
non-ferrous metal.
• Smart switching of pilot contactor so
that it does not switch under load.
• Low fan noise at idle.
• Modular construction for easy servicing.
CUTTING AND GOUGING
CAPABILITY
The PRO-CUT 60 is rated at 60 amps, 115 VAC,
at 60% duty cycle on a 10 minute basis or 45
amps, 115VAC, at 100% duty cycle. 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.
LIMITATIONS
Do not exceed output current and duty cycle rating of machine. Do not use the PRO-CUT 60 for
pipe thawing.
CONTROLS AND SETTINGS
3. STATUS LED DISPLAY: The following
machine conditions are displayed:
MACHINE ON LED: The green POWER ON
LED glows when the POWER LINE SWITCH
is in the ON position and AC power is connected to the machine.
OUTPUT ON LED: The OUTPUT ON LED
glows when the pilot arc starts and remains
glowing during cutting.
AIR PRESSURE LED: The AIR PRESSURE
LED glows whenever there is adequate air
pressure (above 50 psi).
THERMAL LED: The THERMAL LED glows
when the machine overheats.
FAULT LED (MALFUNCTION LED): The
FAULT LED glows/blinks if a short circuit has
occurred in the torch, in the machine, or when
the air pressure is too low.
SAFETY LED: The SAFETY LED glows when
there is an operating problem with the
machine, torch, or torch consumables.
All operator controls and adjustments are located
on the Case Front Assembly of the PRO-CUT 60.
See Figure B.1 for the location of each control.
1. SAFETY RESET BUTTON:The SAFETY
RESET BUTTON is pressed to resume operation after the SAFETY LED glows and the
operating problem is cleared.
2. PURGE/RUN SWITCH: This switch controls
the air supply to the machine. In the PURGE
position, air flows continuously through the
torch to allow for the adjustment of air pressure. Note that the output is disabled in this
mode. In the RUN position, air flows through
the torch when the torch trigger is activated.
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4. OUTPUT CURRENT CONTROL: The OUT-
PUT CURRENT CONTROL adjusts the current flow for maximum cutting results. See
User Chart Range guide on machine's nameplate for recommended range settings based
on thickness of steel being cut.
5. ON/OFF POWER SWITCH: Turns the
machine ON or OFF.
PRO-CUT 60
OPERATION
B-4
➂
➃
➁
➀
1. Safety Reset Button, 2. Purge/Run Switch, 3. Status LED Display,
4. Output Current Control, 5. ON/OFF Power Switch
➄
FIGURE B.1 Control Panel Keys
OPERATING STEPS
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.
1. Turn the machine's ON/OFF POWER
SWITCH to OFF position.
2. Connect air supply to the machine.
3. Turn on main AC power supply to the
machine.
4. Turn the machine's ON/OFF POWER
SWITCH to ON.
NOTE: If the SAFETY LED glows, press the
SAFETY RESET button. If there is no problem, the SAFETY LED will go off. If the SAFETY LED remains on, turn the ON/OFF
POWER SWITCH to OFF and refer to the
TROUBLESHOOTING GUIDE in the TROUBLESHOOTING AND REPAIR SECTION of
this manual for a recommended course of
action.
5. Set the PURGE/RUN switch in the PURGE
position.
- The air flow starts.
- The AIR PRESSURE LED glows.
6. Adjust air pressure to 60 psi with the air
flowing.
7. Move the PURGE/RUN SWITCH to RUN.
-Postflow air flows for 20 seconds.
- The green POWER ON LED glows.
- The fan starts.
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During this time, the pilot arc immediately
starts when the torch trigger is pulled. After
20 seconds, air preflows for two seconds.
PRO-CUT 60
B-5
OPERATION
8. Pull the torch trigger to cut.
- OUTPUT ON LED glows.
If postflow has not timed out, the pilot arc
lights immediately.
If postflow air has timed out (after 20 seconds), air preflows for two seconds before
pilot arc lights.
If the arc is not transferred by bringing plasma
in contact with the work with in 2.5 seconds,
the pilot arc shuts off.
9. Make a cut.
10. Stop cutting by releasing the torch trigger.
- Arc stops.
- Postflow air continues for 20 seconds.
- To continue cutting, repeat Step 8.
11. Turn ON/ OFF POWER SWITCH to OFF
when job is done.
If the SAFETY LED glows at any time during operation, check the following:
-Torch consumables are assembled properly.
Machine will not start if they are not properly
in place.
Use Pilot Arc Properly
The pilot arc transfers the arc to the work piece for
cutting. Do not start the pilot arc repeatedly over
short periods of time. This could reduce consumable life. Start the pilot arc and then make and finish the cut before releasing the trigger.
If the pilot arc sputters or does not start each time
the torch trigger is pulled, check the consumable
for wear or high air pressure. If either is found,
take proper action.
Cutting and Gouging Recommendations
General
1. Make a continuous cut. Do not pause
during cutting, gouging, or at the end of
the work piece. Stopping and starting
causes poor cuts and results in poor
machine operation. In addition, it
reduces consumable life.
2. Position the torch so that dross and hot
air cannot be deflected into the torch.
-Nozzle condition. The nozzle must be clean.
After the problem is corrected or no problem is
found, press the SAFETY RESET button. If
SAFETY LED goes out, machine is ready for use.
If SAFETY LED continues to glow, refer to the
TROUBLESHOOTING GUIDE in the TROUBLESHOOTING AND REPAIR SECTION of this
manual for a recommended course of action.
CUTTING PROCEDURE
RECOMMENDATIONS
For best results, use proper cutting or gouging
procedures. Plasma arc cutting is a very economical process when used properly. Improper
procedures or equipment use will result in poor
quality work and high operating costs. The following procedures will help you get maximum performance from your PRO-CUT 60.
3. Do not drag the nozzle when cutting
above the mid-range setting. Above mid
range, always hold the torch 1/8" away
from the work piece.
4. Proper drag cup/shield cup use gives you
maximum nozzle and consumable life.
- When operating in the blue or red current
ranges, use a drag cup when possible.
- When operating in the yellow range, use a
drag cup or a shield cup.
5. Use the proper machine setting for the
work to be done. Adjusting the machine
to maximum output does not produce the
best cutting in most situations.
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PRO-CUT 60
6. Use nozzle with the largest orifice that gives
the best cut for the work being done. This produces the best work results and consumable
life. As the size of the nozzle orifice increases,
its current capability increases. Therefore, the
nozzle used for cutting or gouging work must
be able to handle the current needed to give
the best cutting results. A nozzle working
beyond its current capability overheats causing poor performance. Never use the .035
inch (0.8mm) nozzle when the current output
is above the yellow current range.
7. Use the S24114 Drag Cup when the output
current is in the red range to protect the torch
from dross and the effects of improper arcing
conditions.
NOTE:The S24114 Drag Cup should not be
used at very low outputs.
8. Do not allow your body or the torch cable to
touch hot surfaces.
9. Refer to the User Chart Range guide on the
machine's nameplate for recommended output current ranges for the thickness of the
metal being cut.
Cutting Thin Gaug e Sheet Metal
1. Set the OUTPUT CURRENT CONTROL output at mid-range (Yellow range) or below.
2. Pierce a hole in the metal surface to start the
cut. Then, lightly touching the nozzle to the
metal surface, drag the torch along the cut
line.
3. Use the .035" (0.8mm) nozzle for fine cuts.
Larger nozzle sizes work better and provide
longer life, but produce wider kerfs (cuts.)
4. Use a current level setting that is adequate to
produce an acceptable cut at maximum travel
speed. Operating at a current level that
exceeds the requirements needed to cut the
metal results in poor cutting quality and
machine operation.
5. Cut thin gage sections of aluminum, copper,
and other non-ferrous metals using a higher
current range. If acceptable results are not
obtained, use the procedures listed under
Cutting Thick Sections of Metal.
OPERATION
PRO-CUT 60
B-6
3/993/99
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OPERATION
PRO-CUT 60
B-7
Cutting Expanded Metal
1. Cut expanded metal with OUTPUT
CURRENT CONTROL set near the midrange position using the same methods
listed under Cutting Thin Gauge Metal.
Keep the following points in mind:
a. Place a thin piece of scrap metal over
the area to be cut and then cut
through both to make cutting easier.
b. After 30 seconds of cutting expanded
metal, the pilot arc changes from a
bright continuous arc to an arc that
rapidly goes on and off. This
produces a slight spatter. You can
still cut metal when this condition
occurs as long as metal has been cut
in the last five seconds. If metal is not
cut in this condition for more than five
seconds, the arc shuts off and the
machine goes into postflow.
c. The pilot arc duty cycle is 20 seconds
out 80 seconds. If the torch trigger is
continuously pulled and released to
obtain a bright, continuous arc, the
duty cycle limit will be reached and
the arc will be turned off for the duty
cycle limit. When the arc is turned off,
the OUTPUT ON and FAULT LEDs
flash alternately.
Cutting Thick Sections of Metal
1. Set the OUTPUT CURRENT CONTROL
above the mid-range (Red) position.
a. Use the minimum current needed to make
a satisfactory cut.
2. Hold the torch nozzle about 1/8" (3.2mm) from
the cutting surface. Do not let the torch nozzle
touch the work or carry a long arc.
a. Use the S24114 Drag Cup to protect the
torch.
b. Use only the .052" (1.3mm) or the .042"
(1.0mm) nozzles. Do not use the .035"
(0.8mm) nozzle for cutting thick sections of
metal.
3. Start the cut from the edge of the work piece
when possible. Pierce the work piece b y slowly lowering the torch onto the metal at a 30
0
angle. This will blow the dross away from the
torch tip. Slowly rotate the torch to vertical
position as the arc becomes deeper. See
Figure B. 2.
4. Keep moving while cutting. Cut at a steady
speed without pausing.
FIGURE B.2 -- Cutting Thick Piece of Metal.
3030
00
VERVERTICAL ANGLETICAL ANGLE
FOR CUTTINGFOR CUTTING
CUT
90
0
TORCH AT 300ANGLE
TO PIERCE
ROTATE TO
90
0
ANGLE TO CUT
3/993/99
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Gouging Metal
1. Set the OUTPUT CURRENT CONTROL
to maximum.
2. Use the plasma torch with a S24114
Drag Cup assembly or a S24162 shield cup.
3. Bring the torch slowly towards the work
piece at a 300angle, but do not pierce
the work piece. Do not touch the nozzle
to the work piece. See Figure B.3.
a. Blow molten metal away from the torch.
b. If needed, raise the air pressure to
approximately 75 psi to help blow
away molten metal.
c. This process will blow a lot of molten
metal and dross. BE CAREFUL! Blow the
dross away from the torch, away from the
operator and away from flammable
objects.
d. Do not allow the torch cable or body to
contact hot surfaces.
e. Performance is similar to air carbon arc
gouging with a 1/8” (3.2mm) carbon
electrode.
FIGURE B.3 -- Gouging Metal.
OPERATION
PRO-CUT 60
B-8
ANGLE
MAINTAINED
THROUGHOUT
GOUGE
TORCH HELD AT
30
0
ANGLE
THROUGHOUT GOUGE
ANGLE
OF APPROACH
3/99
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NOTESB-9
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PRO-CUT 60
TABLE OF CONTENTS
Section C
- ACCESSORIES SECTION -
Page
Accessories............................................................................................................ Section C
Accessories....................................................................................................................C-1
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PRO-CUT 60
OPTIONS/ACCESSORIES
DRAG CUP ASSEMBLY (S24114)
The drag cup protects the torch by preventing the
torch from touching the workpiece.
SHIELD CUP ASSEMBLY (S24162)
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.
TORCH SPARE PARTS KIT (K872)
(Included with each machine)
Includes:
Shield Cup Asmbly S24162
Nozzles:
.035 (0.9mm) Orifice
S18497-1D
1
.042 (1.1mm) Orifice
S18497-2D
1
.052 (1.3mm) Orifice
S18497-3D
1
.078 (Gouging) (2.0mm)Orifice
S18497-4D
1
Electrode
S18752D
1
Drag Cup Asmbly S24114
Wrench S18808
Tool Box
S19576-1
1
These parts come in a 5-pack.
ACCESSORIES
PRO-CUT 60
C-1
3/99
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TABLE OF CONTENTS
Section D
- MAINTENANCE SECTION -
Page
Maintenance ..................................................................................................... Section D
Safety Precautions...................................................................................................D-1
Capacitor Discharge Procedure......................................................................D-1 - D-2
Routine and Periodic Maintenance..........................................................................D-3
3-D Exploded View ...................................................................................................D-4
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PRO-CUT 60
D-1
MAINTENANCE
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK can kill.
• Only qualified personnel
should perform this maintenance.
• Turn the input power OFF at
the disconnect switch or fuse
box before working on this
equipment.
• Failure to follow this capacitor discharge procedure can
result in electric shock.
• Do not touch electrically hot
parts.
CAPACITOR DISCHARGE PROCEDURE
PROCEDURE DESCRIPTION
This procedure must be performed before performing any maintenance inside the machine.
MATERIALS NEEDED
High resistance, high wattage resistor
( 25-1000 ohms, 25 watts minimum).
Insulated pliers
Insulated gloves
DC Volt/Ohm meter (Multimeter)
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PRO-CUT 60
MAINTENANCE
CAPACITOR DISCHARGE PROCEDURE
D-2
PROCEDURE
NOTE: See Figure D.1.
1. Disconnect input power to the machine.
2. Remove the Left Case Side Assembly.
3. Locate the two capacitors shown Figure D.1
and D.2.
4. Put on the insulated gloves.
5. Grip the middle of the resistor with the
insulated pliers.
6. Touch the resistor leads across the two
capacitor straps as shown for 10 seconds.
a. DO NOT TOUCH THE CAPACITOR
STRAPS WITH YOUR HANDS OR ANY
OTHER PART OF YOUR BODY.
7. Test for zero volts across the capacitor
terminals with a DC voltmeter.
a. Capacitor terminal polarity is marked on
the capacitor straps.
b. If any voltage is measured, REPEAT
PROCEDURE.
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INSULATED
PLIERS
INSULATED
GLOVES
FIGURE D.1 - Capacitor Discharge Procedure
PRO-CUT 60
D-3
MAINTENANCE
ROUTINE AND PERIODIC
MAINTENANCE
1. Disconnect input power supply lines to the
machine before performing periodic maintenance, tightening, cleaning, or replacing
parts. See Figure D.2.
2. Perform Capacitor Discharge Procedure
Perform the following daily:
1. Check that no combustible materials are in
the cutting or gouging area or around the
machine.
2. Remove any debris or materials that could
block the air flow to the machine for cooling.
3. Inspect the torch cable for any slits, puncture
marks in the cable jacket, kinks, or any
condition that could restrict air flow to the
torch. Repair or replace when needed.
Perform Periodically:
Clean inside the machine with a low pressure air
stream. Clean the following components. Refer to
figure D.2.
• Main transformer
• Torch, pilot and work connections
• Spark gap (Inspect for .060 spacing)
• Control board
• Power board
• Heat sink fins
• Fan motor and blade
WARNING
To avoid receiving a high frequency shock, keep
the torch and torch cables in good condition.
Perform the following every three months
or sooner:
1. Check air regulator filters (weekly in dirty
environments).
a. If clogged or dirty, replace them.
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PRO-CUT 60
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