Lincoln Electric PRO-CUTTM 25 User Manual

IM665
RETURN TO MAIN MENU
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.
Loading...
+ 20 hidden pages