IM665
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PRO-CUT
For use with machines having Code Number:
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.
10661
TM
25
September, 2004
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
OPERATOR’S MANUAL
Copyright © 2004 Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
i
SAFETY
i
WARNING
PLASMA CUTTING or GOUGING can be hazardous.
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN
AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040,
Miami, Florida 33135 or CSA Standard W117.2.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
ELECTRIC SHOCK can
kill.
1.a. The electrode and work (or ground) circuits
are electrically “hot” when the power source is on.
Do not touch these “hot” parts with your bare skin
or wet clothing. Wear dry, hole-free gloves to
insulate hands.
1.b. When the power source is operating voltages in excess of
250 volts are produced. This creates the potential for serious
electrical shock - potentially even fatal.
1.c. Insulate yourself from work and ground using dry insulation.
When cutting or gouging in damp locations, on metal framework such as floors, gratings or scaffolds and when in positions such as sitting or lying, make certain the insulation is
large enough to cover your full area of physical contact with
work and ground.
1.d. Always be sure the work cable makes a good electrical connection with the metal being cut or gouged. The connection
should be as close as possible to the area being cut or
gouged.
1.e. Ground the work or metal to be cut or gouged to a good electrical (earth) ground.
1.f. Maintain the plasma torch, cable and work clamp in good,
safe operating condition. Replace damaged insulation.
1.g. Never dip the torch in water for cooling or plasma cut or
gouge in or under water.
1.h. When working above floor level, protect yourself from a fall
should you get a shock.
1.i. Operate the pilot arc with caution. The pilot arc is capable of
burning the operator, others or even piercing safety clothing.
1.j. Also see Items 4c and 6.
ARC RAYS can burn.
2.a. Use safety glasses and a shield with the proper filter and cover plates to protect your eyes from
sparks and the rays of the arc when performing or
observing plasma arc cutting or gouging.
Glasses,headshield and filter lens should conform
to ANSI Z87. I standards.
2.b. Use suitable clothing including gloves made from durable
flame-resistant material to protect your skin and that of your
helpers from the arc rays.
2.c. Protect other nearby personnel with suitable non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
to keep fumes and gases away from the breathing zone.
When cutting or gouging on lead or cadmium plated
steel and other metals or coatings which produce highly
toxic fumes keep exposure as low as possible and
below Threshold Limit Values (TLV) using local exhaust
or mechanical ventilation. In confined spaces or in some
circumstances, outdoors, a respirator may be required.
Additional precautions are also required when welding
on galvanized steel.
3.b. Do not use plasma arc cutting or gouging in locations near
chlorinated hydrocarbon vapors coming from degreasing,
cleaning or spraying operations. The heat and rays of the arc
can react with solvent vapors to form phosgene, a highly
toxic gas, and other irritating products.
3.c. Gases used for plasma cutting and gouging can displace air
and cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
3.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your employer’s safety practices.
sparks and hot materials from plasma cutting or gouging can
easily go through small cracks and openings to adjacent
areas. Avoid cutting or gouging near hydraulic lines. Have a
fire extinguisher readily available.
4.b. Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the equipment being used.
4.c. When not cutting or gouging, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard.
4.d. Do not cut or gouge tanks, drums or containers until the proper steps have been taken to insure that such procedures will
not cause flammable or toxic vapors from substances inside.
They can cause an explosion even though they have been
“cleaned.” For information purchase “Recommended Safe
Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
4.e. Vent hollow castings or containers before heating, cutting or
gouging. They may explode.
4.f. Do nor fuel engine driven equipment near area where plasma
cutting or gouging.
FUMES AND GASES
can be dangerous.
3.a. Plasma cutting or gouging may produce
fumes and gases hazardous to health. Avoid
breathing these fumes and gases.When cutting
or gouging, keep your head out of the fumes.
Use enough ventilation and/or exhaust at the arc
CUTTING SPARKS can
cause fire or explosion.
4.a..Remove fire hazards from the plasma cutting or gouging area. If this is not possible, cover
them to prevent the cutting or gouging sparks
from starting a fire. Remember that welding
Apr. ‘93
ii
SAFETY
ii
4.g. Sparks and spatter are thrown from the plasma arc. Wear
safety glasses, ear protection and oil free protective garments
such as leather gloves, heavy shirt, cuffless trousers, high
shoes and a cap over your hair. Wear ear plugs when cutting
or gouging out of position or in confined places. Always wear
safety glasses with side shields when in a cutting or gouging
area.
4.h. Connect the work cable to the work as close to the cutting or
gouging area as practical. Work cables connected to the building framework or other locations away from the cutting or
gouging area increase the possibility of the current passing
through lifting chains, crane cables or other alternate circuits.
This can create fire hazards or overheat lifting chains or
cables until they fail.
CYLINDER may explode
if damaged.
5.a. Use only compressed gas cylinders containing the correct gas for the process used and
properly operating regulators designed for the
gas and pressure used. All hoses, fittings, etc.
should be suitable for the application and maintained in good
condition.
5.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
5.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from plasma cutting or gouging, arc weld-
ing operations and any other source of heat, sparks,
or flame.
5.d. Never allow any part of the electrode, torch or any other
electrically “hot” parts to touch a cylinder.
5.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
5.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
5.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,”available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
FOR ELECTRICALLY
powered equipment.
6.a. Turn off input power using the disconnect
switch at the fuse box before working on the
equipment.
6.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s recommendations.
6.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
PLASMA ARC can injure.
7.a. Keep your body away from nozzle and
plasma arc.
7.b. Operate the pilot arc with caution. The pilot arc is capable of
burning the operator, others or even piercing safety clothing.
ELECTRIC AND MAGNETIC FIELDS
may be dangerous
8.a. Electric current flowing through any conductor causes localized Electric and Magnetic
Fields (EMF). Cutting or gouging current creates EMF fields around torch cables and cutting
machines.
8.b. EMF fields may interfere with some pacemakers, so operators having a pacemaker should consult their physician
before cutting or gouging.
8.c. Exposure to EMF fields during cutting or gouging may have
other health effects which are now not known.
8d. All operators should use the following procedures in order to
minimize exposure to EMF fields from the cutting or gouging
circuit:
8.d.1. Route the torch and work cables together - Secure
them with tape when possible.
8.d.2. Never coil the torch cable around your body.
8.d.3. Do not place your body between the torch and
work cables. If the torch cable is on your right side,
the work cable should also be on your right side.
8.d.4. Connect the work cable to the workpiece as close as
possible to the area being cut or gouged.
8.d.5. Do not work next to cutting power source.
PRO-CUT 25
Apr. ‘93
NOTES
iv
SAFETY
iv
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suivantes:
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
zones où l’on pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on place
la masse sur la charpente de la construction ou d’autres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer
des risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
du corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
Mar. ‘93
PRO-CUT 25
for selecting a QUALITY product by Lincoln Electric. We want you
Thank You
to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line Product Registration
- Register your machine with Lincoln Electric either via fax or over the Internet.
• For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.
• For On-Line Registration: Go to our
“Product Registration”. Please complete the form and submit your registration.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
TABLE OF CONTENTS
Page
Installation.......................................................................................................................Section A
Technical Specifications.......................................................................................................A-1
Safety Precautions ...............................................................................................................A-2
Select Proper Location .........................................................................................................A-2
Stacking................................................................................................................................A-2
Tilting....................................................................................................................................A-2
High Frequency Interference Protection...............................................................................A-2
Input Electrical Connections.................................................................................................A-2
Gas Input Connections.........................................................................................................A-3
Output Connections..............................................................................................................A-3
Torch .............................................................................................................................A-3
Operation.........................................................................................................................Section B
Safety Precautions ...............................................................................................................B-1
Description ...........................................................................................................................B-1
Preheat Temperature for Plasma Cutting.............................................................................B-1
User Responsibility...............................................................................................................B-2
Operational Features and Controls ......................................................................................B-2
Design Features and Advantages ........................................................................................B-2
Cutting Capability .................................................................................................................B-3
Consumable Life ..................................................................................................................B-3
Limitations ............................................................................................................................B-4
Controls and Settings ...........................................................................................................B-4
Pilot Arc Discussion..............................................................................................................B-5
Procedure Recommendations..............................................................................................B-6
General .........................................................................................................................B-6
Thin Gauge Sheet and Material up to 3/8” ....................................................................B-6
Suggestions for Extra Utility from the PRO-CUT System .............................................B-6
Accessories.....................................................................................................Section C
Genuine Lincoln Parts ...........................................................................................C-1
General Options / Accessories..............................................................................C-1
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
Routine Maintenance.............................................................................................D-1
Periodic Maintenance............................................................................................D-1
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........................................................................................................Appendix
PRO-CUT 25 ...........................................................................................P357 Series
Torch...............................................................................................................P210-U
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS - PRO-CUT 25 (K1756-1)
INPUT - SINGLE PHASE / 60 HERTZ ONLY
Standard Voltage
115/230/1/50/60Hz 115 V : 15 A @ 20%
1Ø Input Current at Rated Output
115 V : 26.7A@ 60%
115 V : 37.7A@ 35%
230 V : 15 A@100%
230 V : 19 A @ 60%
RATED OUTPUT
Duty Cycle
20% on 115 V
60% on 115 V
100% on 230 V
35% on 115 V
60% on 230 V
AMPS
15 A
20 A
20 A
25 A
25 A
OUTPUT
Current
Range
12-25 Amps
Open Circuit
Voltage
400 VDC
A-1
Pilot Current
12 Amps
Output
25 A
15 A
20 A
25 A
REQUIRED GAS FLOW RATE REQUIRED GAS INLET PRESSURE
55 PSI @ 240 SCFH
( 3.8 Bar. @ 6800 LHR)
65 to 150 PSI
(4.5 Bar. TO 10.3 Bar.)
RECOMMEND INPUT WIRE AND FUSE SIZES
For all plasma cutting applications
Based on U.S. National Electrical Code
o
AC Input
Voltage
at
50/60
Hertz
230V-1Ø
115V-1Ø
115V-1Ø
115V-1Ø
Ambient Temperature 30
Input Cord
Plug
Size
6-20P or 6-30P or 6-50P
5-15P* or 5-20P* or 5-30P or 5-50P
5-20P* or 5-30P or 5-50P
5-30P or 5-50P
(Super Lag)
Circuit Breaker
(Delay Type)
20 AMPS
15 AMPS
20 AMPS
30 AMPS
Fuse
C or Less
Copper Wire in Conduit
2 Input Supply Wires
#14 (2.5 mm
#12 (4 mm
#12 (4 mm2)
#12 (4 mm2)
Type 75
o
C
AWG (IEC) Sizes
1 Ground Wire
2
)
#14 (2.5 mm
2
)
#12 (4 mm
#12 (4 mm2)
#12 (4 mm2)
2
2
)
PHYSICAL DIMENSIONS
Weight
Height
10.2 in.
260 mm
Width
6.3 in.
160 mm
Depth
16.1 in.
410 mm
Including
Torch Cable
35 lbs.
15.9 kg.
)
* Included with machine
PRO-CUT 25
A-2
INSTALLATION
A-2
Read entire Installation Section before installing the
PRO-CUT 25.
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK CAN KILL.
• Only qualified personnel
should install this machine.
• Turn the input power OFF
at the disconnect switch or
fuse box and discharge input
capacitors before working
inside the equipment.
• Do not touch electrically hot parts.
• Turn the PRO-CUT Power Switch OFF
when connecting power cord to input
power.
___________________________________________
SELECT PROPER LOCATION
Place the PRO-CUT 25 where clean cool air can
freely circulate in and out the side louvers. 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.
HIGH FREQUENCY INTERFERENCE
PROTECTION
The PRO-CUT 25 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
(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 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.
A source of clean, dry air or nitrogen must be supplied
to the PRO-CUT 25. 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 4.0 cfm (113 l/min.). Failure to observe these precautions could result in excessive operating temperatures or damage to the torch.
STACKING
The PRO-CUT 25 cannot be stacked.
TILTING
The PRO-CUT 25 must be placed on a stable, level
surface so it will not topple over.
PRO-CUT 25
INPUT ELECTRICAL CONNECTIONS
The PRO-CUT 25 is rated for 115VAC or 230VAC
inputs and will automatically reconnect for the supplied voltage. The machine is shipped from the factory
for operation on 115VAC 15 amp circuits. Use on 15
amp branch circuits will limit cutting output as indicated by the graphics around the output knob. If the output is set at 20 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 20 amp output with 115VAC input, replace
the 15 amp plug on the input cord with the supplied 20
amp plug, and connect the unit to a 20 amp branch
circuit with super lag fuses (or equivalent breaker). To
install the supplied 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.
A-3
INSTALLATION
A-3
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.
-----------------------------------------------------------------------Use of normal 20 amp household breakers may result
in over current trips. If breaker trips occur, reduce the
cutting current output until nuisance trips stop.
To achieve the full 25 amp output capability of the
machine with 115 VAC input, remove the 15 amp or
20 amp plug on the input cord and install a 30 amp or
50 amp plug designed for 115 VAC (NEMA style 530P or 5-50P). Follow the instructions included with
the plug. Connect to an appropriate branch circuit with
a mating receptacle.
The PRO-CUT 25 performs best when connected to
230VAC inputs. To change over to 230VAC operation,
install a 230VAC plug with a current rating equal to or
greater than 20 amps.
For use on engine drives, keep in mind the above
input draw restrictions and the following precaution.
The PRO-CUT 25 can be operated on engine driven
generators as long as the 230 volt auxiliary meets the
following conditions:
• The AC waveform peak voltage is below 400 volts*.
• The AC waveform frequency is between 45 and 65
Hz.
• The RMS voltage of the AC waveform is always
greater than 208VAC *.
for 115 VAC input divide these values in half
*
The following Lincoln engine drives meet these conditions when run in the high idle mode:
Ranger 200 & 250 engine drives
Commander 300, 400, & 500 engine drives
Some engine drives do not meet these conditions (eg
Miller Bobcats, etc). Operation of the PRO-CUT 25 is
not recommended on engine drives not conforming to
these conditions. Such combinations may overvoltage
the PRO-CUT 25 power source.
GAS INPUT CONNECTIONS
Supply the PRO-CUT 25 with clean compressed air or
nitrogen.
• Supply pressure must be between 80 psi
and 150 psi.
• Flow rate should be approximately 4.0
cfm (113 I/min.).
NOTE: Oil in the air supply to the PRO-CUT 25 can
cause severe problems. Use only a clean air
supply.
Compressed gas can be supplied either through the air
•
fitting supplied with the machine or through the
BSPP
thread at the rear of the machine. To use the air
fitting supplied with the machine (packaged in the consumable kit), apply teflon tape to the fitting threads and
install the fitting in the port at the rear of the machine.
• If compressed air is being used, it is highly recommended that an inline filter be installed in the air
supply line ahead of the air connection to the PROCUT 25.
• A standard nominal 5 micron inline filter is recommended; however, for optimum performance,select
a prefilter with a 3 micron absolute rating. If these filter ratings are unavailable, anything with a rating
less than, or equal to, 20 micron would be acceptable to use. In line 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 be a 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 25, the filter element
should be replaced at or before the pressure drop
reaches 8 psi. Be sure to select a filter that will
accommodate the necessary flow rating for the
PRO-CUT 25 as specified in the Installation section
of this instruction manual under the Gas Input
Connections heading.
1
/4-19
PRO-CUT 25
A-4
NOTE: When using nitrogen gas from a cylinder, the
cylinder must have a pressure regulator.
• Maximum psi from a nitrogen gas cylinder to
the PRO-CUT 25 regulator should never
exceed 150 psi.
• Install a hose between the nitrogen gas
cylinder regulator and the PRO-CUT 25
gas inlet
.
CYLINDER could explode if damaged.
INSTALLATION
WARNING
• 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.
A-4
• Never allow the cutting torch to touch the
cylinder.
• Keep cylinder away from live electrical
parts.
• Maximum inlet pressure 150 psi.
__________________
OUTPUT CONNECTIONS
Torch
The PRO-CUT 25 is sent from the factory with a 15’
PCT 20 cutting torch installed. Additional cutting torches can be ordered from the K1615 series. Hand-held
torches come with 15' or 25’ cables.
Read and understand this entire section before operating the machine.
PRO-CUT 25
B-1
OPERATION
B-1
SAFETY PRECAUTIONS
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.
DESCRIPTION
The PRO-CUT 25 is a constant current, continuous
control plasma cutting power source. It provides superior and reliable starting characteristics, cutting visibility and arc stability. 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 25 comes standard with an air regulator and pressure gauge. The machine also comes with
an input power cord. Hand-held torches are available
in 15' or 25' cable. Consumables are included with
each Pro-Cut purchase so that cutting can begin right
out of the box. Consumables can also be ordered as
individual packages.
The PRO-CUT 25 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.
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.
• Operate the pilot arc with caution. The
pilot arc is capable of burning the
operator, others or even piercing
safety clothing.
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).
Observe additional Safety Guidelines detailed in
the beginning of this manual.
PRO-CUT 25
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
flowrate 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.
OPERATIONAL FEATURES AND
CONTROLS
The PRO-CUT 25 comes with an ON/OFF POWER
SWITCH, OUTPUT CURRENT CONTROL, and
PURGE BUTTON.
DESIGN FEATURES AND
ADVANTAGES
The PRO-CUT 25 design makes plasma cutting
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.
- Continuous control, 12 - 25 amps.
- Reliable touch start mechanism for plasma arc initiation.
- Rapid arc restrike for fast cutting of expanded metal.
- Input over voltage protection.
- Bright 3.0 second timed pilot arc.
- Purge momentary push button.
- Air regulator and pressure gage included.
- Parts-in-Place mechanism to detect proper installation of consumables and torch.
- Latching Parts-in-Place mechanism. Requires the
operator to turn the machine off and then on to
reset.
- Preflow/Postflow timing. Preflow is eliminated if arc
is re-initiated in Postflow.
- Thermostatic Protection.
- Solid state over-current protection.
- Automatic reconnect for 115 VAC or 230 VAC
inputs.
- Light weight and portable design for industrial use.
- 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.
PRO-CUT 25
B-3
OPERATION
B-3
CUTTING CAPABILITY
The PRO-CUT 25 is rated at 25 amps, at 35% duty cycle on a 10 minute basis. 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 25 when cutting mild steel. (The graph plots cut thickness vs.
torch travel speed with a torch standoff of 0.15".)
Lincoln's PRO-CUT 25
Cut Capacity Chart
80
60
40
80% of Maximum Speed
20
Recommended Torch Travel Speed (IPM)
0
0.250
0.3750.125
Metal Thickness (Inches)
Figure B.1
CONSUMABLE LIFE
The expected life for the PRO-CUT 25's electrode under normal operating conditions is approximately 1000
starts/cuts. An erosion of .060" is typical for end of electrode life, however, the electrode life may last longer. A
green and erratic arc will indicate definite electrode failure and the electrode should be replaced immediately.
It is recommended that consumables be replaced in complete sets. (Example: Electrode and Nozzle). This will
maximize the performance of the PRO-CUT 25 system.
PRO-CUT 25
B-4
30
0
VER
TICAL ANGLE
FOR CUTTING
OPERATION
B-4
LIMITATIONS
Do not exceed output current and duty cycle rating of
machine. Do not use the PRO-CUT 25 for pipe thawing.
CONTROLS AND SETTINGS
PRESSURE REGULATOR
CAP
When preparing to cut, 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.
• Turn the main power and the machine power switch
on.
- The fan should start.
- The pre-charge circuit will operate for 3 seconds,
then the green "Power" LED should turn on.
• 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 65 PSI for 15’ or 25’
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.
• 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. (Exceptions: the first
time that the trigger is pulled after the machine is
turned on, or after a thermal tripout, will be
ignored. This is a safety feature to prevent the
pilot arc from firing unexpectedly or if the torch
button is pressed because it is laying up against
something. The other exception is if 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.
- When the arc is brought within 1/8” - 1/4" from
the work piece: the arc will transfer, the current
will ramp to the setting on the control panel, and
the cut can last indefinitely (or until the duty
cycle of the Pro-Cut is exceeded).
• Pierce the work piece by slowly lowering the torch
onto the metal at a 30
0
angle away from the operator. This will blow the dross away from the torch tip.
Slowly rotate the torch to vertical position as the arc
becomes deeper.
TORCH AT 300ANGLE
0
30
TO PIERCE
ROTATE TO
0
ANGLE TO CUT
90
• Be sure that the work lead is clamped to the workpiece before cutting.
• Set the output current control knob at maximum
position for higher 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.
1
Maximum output requires a 30 amp input circuit and breaker. Refer to the
Technical Specifications for proper input circuit guidelines.
PRO-CUT 25
0
90
VER
TICAL ANGLE
FOR CUTTING
1
CUT
• 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.
B-5
OPERATION
B-5
Leading Angle
5° - 15°
Direction of Travel
10° - 20°
Arc Lag
•
Use a 5° - 15° leading angle in the direction of the cut.
• 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.
• Clean spatter and scale from the nozzle frequently.
• If the "SAFETY" LED lights at any time; check the
following:
• After the problem is found, or if there is nothing
apparently wrong, reset the machine by turning the
power switch OFF and then ON again. (It is possible for electrical noise to trip the safety circuit on
rare occasions. This should not be a regular occurrence.)
WARNING
ELECTRIC SHOCK CAN KILL.
• Turn off machine at the disconnect
switch on the front of the machine
before tightening, cleaning or replacing
consumables.
----------------------------------------------------------------------------
• If the machine does not reset or continues to trip,
consult the Troubleshooting Section.
• Use the proper cutting procedures referred to in
Procedure Recommendations.
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.
• 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 .062”. 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.
PRO-CUT 25
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.
B-6
OPERATION
B-6
PROCEDURE RECOMMENDATIONS
When properly used, plasma arc cutting is a very economical process. Improper use will result in a very
high operating cost.
General - In All Cases
• Follow safety precautions as printed throughout
this operating manual and on the machine.
• 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.
• The nozzle may be dragged on the metal sur-
face, touching it lightly to the surface. NOTE:
The use of a drag cup with the PRO-CUT is
not recommended. The increased standoff
distance reduces the overall performance of
the PRO-CUT.
Torch Standoff
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
safety 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. Do not
allow torch cable or body to contact hot surface.
2. To improve consumable life, here are some sug-
gestions that may be useful:
a. Make sure the air supply to the Pro-Cut is
clean and free of oil. Use several extra in line
filters if necessary.
b. Minimize dross buildup on the nozzle tip by
starting the cut from the edge of the plate
when possible.
c. 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.
DRAG thru 1/16”
DRAG thru 1/16"
Standoff
Standoff
• Where possible, start the cut from the edge of
the work piece.
• Keep moving! A steady speed is necessary.
Do not pause.
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.
----------------------------------------------------------------------------
PRO-CUT 25
d. Reduce the number of pilot arc starts without
transferring to the work.
e. Reduce the pilot arc time before transferring
to the work.
f. Set air pressure to recommended setting. A
higher or lower pressure will cause turbulence
in the plasma arc, eroding the orifice of the
nozzle tip.
g. 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.
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 25.
• 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.
GENERAL OPTIONS /
ACCESSORIES
The following options/accessories are available for
your PRO-CUT 25 from your local Lincoln Distributor.
S22147-028 - VORTECH™ nozzle with an .028” (0.7
mm) Orifice
S22149 - Electrode - replacement electrodes for cutting.
S22150 - Shield Cup - This shields the nozzle and
provides more visibility to the workpiece. Note the
shield cup does not prevent the torch tip from touching
the workpiece.
K1615 Series - PCT 20 Torches come in 15’ and 25’
lengths. Refer to the Parts Pages in the rear of this
manual for Torch parts.
PRO-CUT 25
D-1
MAINTENANCE
D-1
WARNING
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.
---------------------------------------------------------------------
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:
- Printed circuit boards and heat sinks
- Power switch
CAUTION
• When using a low pressure aistream, wear
appropiate eye protection.
------------------------------------------------------------------------
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. Inspect the cable periodically for any slits or puncture marks in the cable jacket. Replace if necessary. Check to make sure that nothing is crushing
the cable and blocking the flow of air through the
air tube inside. Also, check for kinks in the cable
periodically and relieve any so as not to restrict the
flow of air to the torch.
PERIODIC MAINTENANCE
WARNING
ELECTRIC SHOCK CAN KILL.
• Turn off machine at the disconnect
switch on the front of the machine
before tightening, cleaning or replacing
consumables.
----------------------------------------------------------------------------
Change consumables as required.
THERMAL PROTECTION
Thermal Detection Devices 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
Detection Devices will prevent output voltage or current.
These Detection Devices 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. In the event that the capacitor
voltage is too high, the protection circuit will prevent
output.
REPLACEMENT OF INTERNAL FUSES
The PRO-CUT 25 has additional protection provided
to some circuits through internal fuses. For replacement of those fuses proceed as follows:
1. Turn off the power to the unit and remove the
input plug.
2. Allow the machine to stand for 5 minutes to let
the input capacitors discharge.
3. Remove the machine cover.
4. Replace the blown fuse with a new 0.5A 500V
slowblow fuse or 32A 400V fuse as appropriate.
NOTE: If the fuse blows again after power is restored,
PRO-CUT 25
the cause could be an internal breakdown in
the power unit. In this case, take the unit to an
authorized Lincoln Field Service Shop.
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.
E-1
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 you local Lincoln Authorized Field
Service Facility.
If you do not understand or are unable to
perform the Recommended Course of
Action safely, contact you 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 25
E-2
PROBLEMS
(SYMPTOMS)
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
POSSIBLE AREAS OF
MISADJUSTMENTS
RECOMMENDED
COURSE OF ACTION
E-2
Input circuit breaker trips repeated.
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. This may be normal. If output is
set to maximum a 30 amp circuit
is required. See Technical
Specification page.
2. Install a larger input circuit or turn
the output control to a lower
amperage.
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. Check the fuses on the input
board.
1. Disconnect input power from the
machine. Check that connectors
on harness between Control Bd.
and Power Bd. are properly seated.
If all recommended possible areas of
misadjustment have been checked
and the problem persists, Contact
your local Lincoln Authorized
Field Service Facility.
2. Possible faulty Control Board.
3. Possible faulty Power Board.
The Thermal LED does not go out.
1. Check consumables - The safety
light lights when an unsafe condition exists either at the torch or
somewhere else within the system.
2. Possible faulty Power 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 25
E-3
PROBLEMS
(SYMPTOMS)
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
POSSIBLE AREAS OF
MISADJUSTMENTS
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. Reconnect Board may be
faulty.
b. The main gas solenoid assem-
bly may be faulty. Check or
replace.
c. Possible faulty Control board.
2. 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.
3. Check for proper trigger switch
operation. Remove the torch cable
assembly from the Pro Cut and
test for continuity between 1 and 2
at the Green 4 Pin Connector
when the trigger switch is
depressed and no continuity when
the switch is not depressed.
Replace the trigger switch or torch
cable if defective.
If all recommended possible areas of
misadjustment have been checked
and the problem persists, Contact
your local Lincoln Authorized
Field Service Facility.
4. 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 25
E-4
PROBLEMS
(SYMPTOMS)
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
POSSIBLE AREAS OF
MISADJUSTMENTS
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.
2. Make sure the air pressure is set
at 65 psi.
3. Make sure there are no kinks or
restrictions for air flow in the torch
cable. Replace cable as needed.
4. 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.
5. Possible fault in Control board.
1. Check the torch consumables to
be sure they are in tight, not dirty
or greasy and in good shape.
Replace if necessary.
2. Make sure the air pressure is set
at 65 psi.
3.
Possible fault in Control board.
If all recommended possible areas of
misadjustment have been checked
and the problem persists, Contact
your local Lincoln Authorized
Field Service Facility.
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 65 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 25
E-5
PROBLEMS
(SYMPTOMS)
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
POSSIBLE AREAS OF
MISADJUSTMENTS
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 Control
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 25
E-6
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
STATUS BOARD INDICATORS
E-6
SYMPTOM
The Air Low LED is lit
The Safety LED is lit and steady
The Thermal LED is lit
CHECK
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 55 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. Turn the power OFF and then ON. If torch and consumables are
properly installed, the Safety LED should turn off. Normal cutting
or gouging can resume.
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. The input voltage is not within ±10% of rated values.
4. Possible faulty Control board.
PRO-CUT 25
F-1
WORK CLAMP
DIAGRAMS
EV2
PT
12VDC
F-1
WRK
D10
240uH
RHRG30120
C26
Q1a,b,c
8A
+12VDC_SW TRANSFER
T2
IRG4BC30W
4.7nF/4kV
AC
NZL (2)
RL1
RHRG30120
D11
SECPRI
C12
1500uF/250V
C1a,b +
15K/3WR115K/3W
CP
CP
C14
Q2a,b,c
2uF/400V
R2
C2a,b + C2b
2.2uF/400V
R24
IRG4BC30W
1500uF/250V
AC
6.8k/5W
EL (3)
SH1
213
CN3
0.010
SH- SH+
4.7nF/4kV
C13
CN2
4
99029
5-3-99
4
CN1
17
FULL SCHEMATIC: 98044
NOT ALL COMPONENTS SHOWN
PC-25
3
5
9
6
10
12 18 14 1 11 4 13 7 19 24 21 23 8 1 2 3
EV1
+15Vrms
15 16
2
22
20
POT_CCW
POT_CW
POT_WIPER
OUTPUT
TRIGGER
EV2 DRIVER
EV1 DRIVER
TRANSFER
TRANSFER SW
OVLOAD
SEC GND
+8V_SW
+12VDC_SW
V_OUT
+12VDC
24
22
23
V+
1 2 18 14 7 15 4 11 5 16 10 12 13
PRO-CUT 25 - WIRING DIAGRAM
SW1
ACCPCP
RL2
R1
RL3
A
300uH
INPUT
RL2
RL2
F1
1A/250V
10/10W
B
115/230/1/50/60 VAC
SAFETY
SEC GND
OVLOAD
PS1
PS2
15VAC
15VAC
SAFETY
+28VDC
SEC GND
OVLOAD
115/230
AC
2143567
+12VDC
8
CN1
RL1
T1
RL2
115VAC
L1
V1
V2
230VAC
115V
230V
RL1
L1
FULL SCHEMATIC: 98056
SIPC25
NOT ALL COMPONENTS SHOWN
FN1
861793
CN1
EV1
12VDC
NC
COM
NO
PS1
FULL SCHEMATIC: 99016
NOT ALL COMPONENTS SHOWN
SPA25
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..
PRO-CUT 25
WARNING
Spanish
AVISO DE
PRECAUCION
● Do not touch electrically live parts or
electrode with skin or wet clothing.
● Insulate yourself from work and
ground.
● No toque las partes o los electrodos
bajo carga con la piel o ropa mojada.
● Aislese del trabajo y de la tierra.
● Keep flammable materials away.
● Mantenga el material combustible
fuera del área de trabajo.
● Wear eye, ear and body protection.
● Protéjase los ojos, los oídos y el
cuerpo.
French
ATTENTION
German
WARNUNG
Portuguese
ATENÇÃO
Japanese
Chinese
Korean
Arabic
● Ne laissez ni la peau ni des vête-
ments mouillés entrer en contact
avec des pièces sous tension.
● Isolez-vous du travail et de la terre.
● Berühren Sie keine stromführenden
Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!
● Isolieren Sie sich von den
Elektroden und dem Erdboden!
● Não toque partes elétricas e elec-
trodos com a pele ou roupa molhada.
● Isole-se da peça e terra.
● Gardez à l’écart de tout matériel
inflammable.
● Entfernen Sie brennbarres Material!
● Mantenha inflamáveis bem guarda-
dos.
● Protégez vos yeux, vos oreilles et
votre corps.
● Tragen Sie Augen-, Ohren- und Kör-
perschutz!
● Use proteção para a vista, ouvido e
corpo.
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
● Keep your head out of fumes.
● Use ventilation or exhaust to
remove fumes from breathing zone.
● Turn power off before servicing.
● Do not operate with panel open or
guards off.
WARNING
● Los humos fuera de la zona de res-
piración.
● Mantenga la cabeza fuera de los
humos. Utilice ventilación o
aspiración para gases.
● Gardez la tête à l’écart des fumées.
● Utilisez un ventilateur ou un aspira-
teur pour ôter les fumées des zones
de travail.
● Vermeiden Sie das Einatmen von
Schweibrauch!
● Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
● Mantenha seu rosto da fumaça.
● Use ventilação e exhaustão para
remover fumo da zona respiratória.
● Desconectar el cable de ali-
mentación de poder de la máquina
antes de iniciar cualquier servicio.
● Débranchez le courant avant l’entre-
tien.
● Strom vor Wartungsarbeiten
abschalten! (Netzstrom völlig öffnen; Maschine anhalten!)
● Não opere com as tampas removidas.
● Desligue a corrente antes de fazer
serviço.
● Não toque as partes elétricas nuas.
● No operar con panel abierto o
guardas quitadas.
● N’opérez pas avec les panneaux
ouverts ou avec les dispositifs de
protection enlevés.
● Anlage nie ohne Schutzgehäuse
oder Innenschutzverkleidung in
Betrieb setzen!
● Mantenha-se afastado das partes
moventes.
● Não opere com os paineis abertos
ou guardas removidas.
Spanish
AVISO DE
PRECAUCION
French
ATTENTION
German
WARNUNG
Portuguese
ATENÇÃO
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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