Lincoln Electric IM665 User's Manual
Contents
1. Section D Safety PreCautions iii D 1 Routine Maint nanc D 1 Periodic Maintenance su D 1 Troubleshooting ss Section Safety E E 1 How to Use Troubleshooting Guide E 1 Troubleshooting Guide iiir cene dente eed eed E 2 Wiring Diagrams c conc coria a Section F Wiring ES F 1 Parts 141 1 P Appendix PRO CUT 25 x n eed co Ein eee ee ec dde P357 Series INSTALLATION TECHNICAL SPECIFICATIONS PRO CUT 25 K1756 1 INPUT SINGLE PHASE 60 HERTZ ONLY Standard Voltage 10 Input Current at Rated Output 115 230 1 50 60Hz 15 20 26 7A 60 37 7A 35 15 A 100 19A 60 RATED OUTPUT 20 on 115 V 15A 100 on 230 V 20A 35 on 115 V 25 60 on 230 V 25A OUTPUT Current Open Circuit Pilot Current Range Voltage 12 25 Amps 400 VDC 12 Amps REQUIRED GAS FLOW RATE REQUIRED GAS INLET PRESSURE 55 PSI 240 SCFH 65 to 150 PSI 3 8 Bar 6800 LHR 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 Ambient Temperature 30 C or Less Output Input Input Cord Fuse Type 75 C Voltage Plug Super Lag Copper Wire in Conduit Size Circuit Breaker AWG IEC Sizes Delay Type 2 Input Supply Wires 1 Ground Wire 230V 10 6 20P or 6 30P 6 50P 20AM2. ele BEHE TT Saal gl aui Qui al gll guet ag ls LINCOLN e World s Leader in Welding and Cutting Products e 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
3. Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les TRANSFORMATEUR ET Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place PRO CUT 25 LINCOLN for selecting a QUALITY product by Lincoln Electric We want you Thank You io take pride in operating this Lincoln Electric Company product eee 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
4. ZL 8 L EL VEL L vL OL S 99086 714 1 o 02 ser 8 NMOHS SLNINOdJWO9 TIY LON lt z klj soas 77086 OLLVNAHOS TINA 9 NMOHS S1N3NOdIWOO LON 92 94 e 9 00 82 S AINS 0r VASE 9 9 6 owner ld NO INO 111 s A 1 8 19 Ws A n OVAS o Cf m na a Ur NOCOBYOHI a ov ov L lt aa lE lazo 5 gt 7 si Zo 8 al V do do Us 8 tad el a m OWA 09 09 1 062 9 8 E do 99 i Ex m H HN00E 5 MS V NOCORYONI 5 ov ov su m IMS o io EI nove T E 156 dne oa ONIHIM Sc LND Odd LINCOLN E WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Japanese it is BIR Korean Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes los electrodos bajo carga con la piel ropa moja a Aislese del trabajo de tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre e Ber hren Sie keine stromf hrenden Teile oder Elektroden mi
5. 2 Select Proper Location sis A 2 cte A 2 A 2 High Frequency Interference Protection A 2 Input Electrical Connections A 2 Gas Input Connections elec esc recs dde ede ac A 3 Output Connections DEC t A 3 Uem A 3 ecu Section B Safety B 1 Descriptio fo EE B 1 Preheat Temperature for Plasma Cutting B 1 User cente e P B 2 Operational Features and Controls sociscienca eisson iE B 2 Design Features and Advantages B 2 Cutting Capability e Em B 3 Consumable Life B 3 Miele B 4 ero atico Ep ESI 10 E B 4 Pilot Are DISCUSSION EE B 5 Procedure Recommendations ii B 6 ecc M B 6 Thin Gauge Sheet and Material up to 3 8 B 6 Suggestions for Extra Utility from the PRO CUT System B 6 ACCOSSOMIOS c Section C Genuine Lincoln sis C 1 General Options Accessories C 1
6. ANSI Standard 749 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 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 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 Insulate yourself from work and ground using dry insulation 1 When cutting or gouging damp locations metal frame work such as floors gratings or scaffolds and when in posi tions such as sitting or lying make certain the insulation is large enough to cover your full area of physical contact with work and ground Always be sure the work cable makes a good electrical con nection with the metal being cut or gouged The connection should be as close as possible to the area being cut or gouged Ground the work or metal to be cut or gouged to a good elec trical earth ground 1 f Maintain the plasma torch cable and work clamp in good 1 g 1 h safe operating condition Replace damaged insulation Never dip the torch in water for cooling or plasm
7. supply Compressed gas can be supplied either through the air fitting supplied with the machine or through the 4 19 BSPP thread at the rear of the machine To use the air fitting supplied with the machine packaged in the con sumable kit apply teflon tape to the fitting threads and install the fitting in the port at the rear of the machine f compressed air is being used it is highly recom mended that an inline filter be installed in the air supply line ahead of the air connection to the PRO CUT 25 A standard nominal 5 micron inline filter is recom mended however for optimum performance select a prefilter with a 3 micron absolute rating If these fil ter ratings are unavailable anything with a rating less than or equal to 20 micron would be accept able to use In line filter elements will generally filter the air with little restriction to the airflow until the ele ment is about 7596 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 PRO CUT 25 LINCOLN 5
8. plied 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 indicat ed by the graphics around the output knob If the out put is set at 20 amps or greater the input fuse or cir cuit 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 PRO CUT 25 LINCOLN A 3 INSTALLATION A 3 A 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 5 30P or 5 50P Foll
9. 4 INSTALLATION NOTE When using nitrogen gas from a cylinder the cylinder must have a pressure regulator e Maximum psi from a nitrogen gas cylinder to the PRO CUT 25 regulator should never exceed 150 psi e install a hose between the nitrogen gas cylinder regulator and the PRO CUT 25 gas inlet CYLINDER could explode if damaged A 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 e Never allow the cutting torch to touch the cylinder e Keep cylinder away from live electrical parts e 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 torch es can be ordered from the K1615 series Hand held torches come with 15 or 25 cables Read and understand this entire section before oper ating the machine PRO CUT 25 LINCOLN 5 B 1 OPERATION B 1 SAFETY PRECAUTIONS A 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 AR Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone WELDING CUTTING and GOUGING SPARKS can cause fire or e
10. 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 Be sure that the work lead is clamped to the work piece before cutting Set the output current control knob at maximum position for higher cutting speed and less dross for mation 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 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
11. 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 WEB SITE at www lincolnelectric com Choose Quick Links and then 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 A WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life A CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment TABLE OF CONTENTS Page IAS tAN ATOM Section Technical Specifications A 1 P CAUTIONS
12. 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 Connect the work cable to the workpiece as close as possible to the area being cut or gouged Do not work next to cutting power source Apr 93 PRO CUT 25 LINCOLN NOTES LINCOLN SAFETY PRECAUTIONS DE SURETE Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s 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 couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d N
13. there is nothing apparently wrong reset the machine by turning the power switch OFF and then ON again It is possi ble for electrical noise to trip the safety circuit on rare occasions This should not be a regular occur rence A WARNING lt ELECTRIC SHOCK CAN KILL e Turn off machine at the disconnect switch on the front of the machine before tightening cleaning or replacing consumables e f 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 work piece and not for numerous starts without cutting When the pilot arc is started a slight impulse will be felt in the torch handle This occurrence is normal and is the mechanism which starts the plasma arc This impulse can also be used to help troubleshoot a no start condition PRO CUT 25 LINCOLN B 6 PROCEDURE RECOMMENDATIONS When properly used pl
14. 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 5 DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de zona de res Mantenga cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail e Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie fiir gute Be und Entliiftung des Arbeitsplatzes Mantenha seu rosto da fumaca Use ventilac o exhaust o para remover fumo da zona respirat ria 9 fsUPBHEILTASESUCFEU e zzv 24758 else e MAS PARAH AMBHI Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio e D branchez le courant av
15. ERMAL PROTECTION Thermal Detection Devices protect the machine from excessive operating temperatures Excessive temper atures may be caused by a lack of cooling air or oper ating 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 cur rent 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 cor rected 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 replace ment 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
16. GN FEATURES AND ADVANTAGES The PRO CUT 25 design makes plasma cutting uncomplicated This list of design features and advan tages will help you understand the machine s total capabilities so that you can get maximum use from your machine Light weight and portable design for industrial use OPERATION Continuous control 12 25 amps Reliable touch start mechanism for plasma arc initi ation 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 installa tion 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 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 start ing reliability and higher quality cuts PRO CUT 25 LINCOLN 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 unt
17. IM665 P R C U 2 5 September 2004 For use with machines having Code Number 10661 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 thought ful 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 OPERATOR S MANUAL EU pue 1309001 ANSI RAB 8 27 MANC M ZA E Designed and Manufactured Under a Quality Program Certified by ABS Quality Evaluations Inc to ISO 9001 Requirements CERTIFICATE NUMBER 30273 Copyright 2004 Lincoln Global Inc LINCOLN ELECTRIC e 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 A 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 pur chase a copy of Safety in Welding amp Cutting
18. If the fuse blows again after power is restored the cause could be an internal breakdown in the power unit In this case take the unit to an authorized Lincoln Field Service Shop PRO CUT 25 LINCOLN 5 TROUBLESHOOTING E 1 HOW TO USE TROUBLESHOOTING GUIDE A WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty For your safety and to avoid Electrical Shock please observe all safety notes and precautions detailed throughout this manual This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMPTOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external possibili ties that may contribute to the machine symptom 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 Co
19. PS 14 2 5 14 2 5 mm 15 12 4 12 4 115 10 5 20P or 5 30P 5 50P 20 12 4 12 4 115V 10 5 30P or 5 50P 30 AMPS 12 4 mm 12 4 mm Weight Including Torch Cable 35 Ibs 15 9 kg Included with machine PRO CUT 25 LINCOLN 5 A 2 INSTALLATION A 2 Read entire Installation Section before installing the PRO CUT 25 SAFETY PRECAUTIONS A WARNING ELECTRIC SHOCK CAN KILL Only qualified personnel should install this machine 0 e the input power OFF at the disconnect switch or fuse box and discharge input capacitors before working inside the equipment e Do not touch electrically hot parts e 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 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 approximate ly 4 0 113 l min Failure to observe these pre cautions could result in excessive operating temp
20. a cut or gouge in or under water 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 2 b 2 C ARC RAYS can burn 2 Use safety glasses and a shield with the er 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 standards Use suitable clothing including gloves made from durable flame resistant material to protect your skin and that of your helpers from the arc rays 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 LINCOLN 5 Where compressed gases are to be used at the job site spe When not cutting or gouging make certain no part of the elec Do not cut or gouge tanks drums or containers until the prop Vent hollow castings or containers before heating cutting or Do nor fuel engine driven equipment near area where plasma 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 he
21. 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 angle away from the opera tor This will blow the dross away from the torch tip Slowly rotate the torch to vertical position as the arc becomes deeper TORCH AT 30 ANGLE TO PIERCE ROTATE TO 90 ANGLE TO CUT 199 VERTICAL ANGLE FOR CUTTING 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 PRO CUT 25 LINCOLN B 5 OPERATION B 5 5 15 Leading Angle gt Direction of Travel iF 10 20 Arc Lag Use 5 15 leading angle the direction of the
22. ad out of the fumes Use enough ventilation and or exhaust at the arc 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 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 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 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 employ er s safety practices 2 CUTTING SPARKS can cause fire or explosion 4 a Remove fire hazards from the plasma cut ting or gouging area If this is not possible cover them to prevent the cutting or gouging sparks from starting a fire Remember that welding
23. ant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten opere com as tampas removidas Desligue a corrente antes de fazer servico N o toque as partes el tricas nuas e XL7TTL2A 9 AVCWRUD PRE RET BRAY FE e HMDS RK AGS HAS Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes opere com os paineis abertos ou guardas removidas NRIVOAN ERUALEEE CHRRIARRARS SHAE Ro e 20 Sel Sepe Asal WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO it ie BIR Chinese Qai ge Iya dul ale f bi Jaial os uui BALL ge cal ue Aie Ao pha J gail e Ads cuts gall l Jai y e ue Ll gt LEIA E COMPREENDA AS INSTRUCOES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PR TICAS DE SEGURANCA DO EMPREGADOR SRM OBHOX HD OHBRBEE lt K MA CUCRITEOSSXSUEIL HS 85 ET REL BE RC EE Rr de OE AS EL FEE AMENER EZ BU BO 0 SAAD
24. asma arc cutting is a very eco nomical process Improper use will result in a very high operating cost General In All Cases e Follow safety precautions as printed throughout this operating manual and on the machine f 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 DRAG thru 1 16 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 A WARNING e ELECTRIC SHOCK CAN KILL Turn off machine at the disconnect switch on the front of the machine before tightening cleaning or replacing consumables OPERATION B 6 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
25. 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 pre vailing 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 PRO CUT 25 LINCOLN 5 B 2 USER RESPONSIBILITY Because design fabrication erection and cutting vari ables affect the results obtained in applying this type of information the serviceability of a product or struc ture 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 proce dures 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 DESI
26. 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 f 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 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 elec trode 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 After the problem is found or if
27. e jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger zones l on pique le laitier 6 Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s 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 loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les ga
28. ement consumables may cause dam age to the torch or reduce cut quality PRO CUT 25 LINCOLN C1 ACCESSORIES C 1 ALWAYS USE GENUINE LINCOLN ELECTRIC ELECTRODES AND VORTECH NOZZLES e Only Genuine Lincoln Electric consumables yield the best cutting performance for the PRO CUT 25 The patented VORTECH nozzle provides 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 522147 028 VORTECH nozzle with an 028 0 7 mm Orifice 522149 Electrode replacement electrodes for cut ting 22150 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 LINCOLN 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 capaci tor discharge procedure to avoid elec tr
29. era tures 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 HIGH FREQUENCY INTERFERENCE PROTECTION The PRO CUT 25 employs a touch start mechanism for arc initiation which eliminates high frequency emis sions 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 generat ing 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 recom mended Failure to observe these recommended installation procedures may cause improper function of the Pro Cut or possibly even damage to the control system or power supply components INPUT ELECTRICAL CONNECTIONS The PRO CUT 25 is rated for 115VAC or 230VAC inputs and will automatically reconnect for the sup
30. h some pacemakers so opera or flame 5 d Never allow any part of the electrode torch or any other tors having a pacemaker should consult their physician before cutting or gouging electrically hot parts to touch a cylinder 8 c Exposure to EMF fields during cutting or gouging may have 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 cylin ders associated equipment CGA publication Precautions for Safe Handling of Compressed Gases in Oylinders 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 Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s rec ommendations 6 c Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations 8d other health effects which are now not known 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
31. ic 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 break age 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 continu ity 4 Inspect the cable periodically for any slits or punc ture marks in the cable jacket Replace if neces sary 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 A WARNING EN 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 TH
32. ield Service Facility and Power Bd are properly seat ed Possible faulty Control Board Possible faulty Power Board The Thermal LED does not go out Check consumables The safety light lights when an unsafe condi tion exists either at the torch or somewhere else within the sys tem Possible faulty Power board 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 LINCOLN 8 E 3 TROUBLESHOOTING E 3 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS COURSE OF ACTION The Pro Cut powers up properly but 1 Press Purge button on the front of there is no response when the trig the Pro Cut If air does not flow ger is pulled and only the POWER then LED is lit a Reconnect Board may be faulty b The main gas solenoid assem bly may be faulty Check or replace c Possible faulty Control board Remove the handles or barrel of the torch and examine all the con nections Pay attention to location of electrode lead mounting at back of torch head broken trigger and solenoid leads Check for proper trigger switch operation Remove the torch cable assembly from the Pro Cut and te
33. il 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 Recommended Torch Travel Speed IPM 8096 of Maximum Speed 0 125 0 250 0 375 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 LINCOLN B 4 OPERATION B 4 LIMITATIONS Do not exceed output current and duty cycle rating of machine Do not use the PRO CUT 25 for pipe thaw ing CONTROLS AND SETTINGS PRESSURE REGULATOR CAP Pomer Gas PRESS THERMAL SAFETY 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
34. is clean and the problem persists Contact and dry Remove any scale rustlyour local Lincoln Authorized or dross Field Service Facility Check all connections to Control board 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 LINCOLN E 6 TROUBLESHOOTING E 6 Observe all Safety Guidelines detailed throughout this manual STATUS BOARD INDICATORS SYMPTOM The Air Low LED is lit The Safety LED is lit and steady The Thermal LED is lit Make sure there is at least 80 psi connected to the gas connec tion at the back of the machine Press the Purge button and set the regulator to 55 psi The pres sure may increase when air stops flowing but this is normal Do not reset the pressure while the air is OFF Possible faulty Pressure Switch Possible faulty Control board 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 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 The machine s air louvers or fans are obstructed such that ai
35. lvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 contre les chutes dans le cas ou on recoit un choc Ne jamais PR CAUTIONS DE S RET POUR enrouler le c ble lectrode autour de n importe quelle partie dicare LES MACHINES SOUDER Un coup d arc peut tre plus s v re qu un coup de soliel donc REDRESSEUR a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du ray 1 onnement de l arc et des projections quand on soude ou quand on regarde l arc b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc c Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes
36. ow 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 condi tions when run in the high idle mode Ranger 200 amp 250 engine drives Commander 300 400 amp 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 e Supply pressure must be between 80 psi and 150 psi e Flow rate should be approximately 4 0 113 l min NOTE Oil in the air supply to the PRO CUT 25 can cause severe problems Use only a clean air
37. r 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 The input voltage is not within 10 of rated values Possible faulty Control board PRO CUT 25 LINCOLN F 1 L H Jequunu epoo BAIN jueujeoe doi 104 3ueuniedeg ejqiDejr si eui sjeued euo uo eui episui pejsed si epoo sejnomed jenueui siy Aq 10 eq jou JO 5 SIUL LON 91066 OLLVWAHOS TINA NMOHS SIN3NOdWWOO TIY LON 90745 154 62066 66 amp Y e 8 vo 00 EL ZL OL OL v Gb 64 9 8 5 2 gt 3 4 8 5387 885 2 E 9 2 a 9 CN lt 2n E m tc re
38. 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 cial precautions should be used to prevent hazardous situa tions Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equip ment being used trode circuit is touching the work or ground Accidental con tact can cause overheating and create a fire hazard er 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 gouging They may explode cutting or gouging Apr 93 i SAFETY i 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 LE PLASMA can injure plasma arc shoes and a cap over your hair Wear ear plugs when cutting or gouging out of position or in confined places Always wear 7 a Keep your body away from nozzle and safety glasses with side shields when in a cut
39. st 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 LINCOLN 4 TROUBLESHOOTING E 4 Observe all Safety Guidelines detailed throughout this manual When the trigger is pulled air begins 1 Check the torch consumables to be to flow but there is no pilot arc after sure they are not dirty or greasy at least 3 seconds and are in good shape Replace the consumables if necessary Make sure the air pressure is set at 65 psi Make sure there are no kinks or restrictions for air flow in the torch cable Replace cable as needed 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 Possible fault in Control board The air begins to flow and there is al1 Check the torch consumables to very brief arc that snaps out consis be s
40. t Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da pega e terra e 7 amp nf dchsn zucct FSU E GUB Oa CRM ER Xe s AMI d ous aual ay Ast gl uit celal All usu DA daas ule Y Jio Keep flammable materials away e Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflamaveis bem guarda dos ORAPTUSOOM EA m eis A A Jo ALD al gll pis e Ac AI Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschutz Use prote o para a vista ouvido corpo HAUSHERMRELTTF HEBS SOSRSHR ez 119 59 s ESSAI ule Lily vues al ad t daag 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
41. ting or gouging area 4 h Connect the work cable to the work as close to the cutting or 7 b gouging area as practical Work cables connected to the build ing 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 contain ing 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 Always keep cylinders in an upright position securely chained to an undercarriage or fixed support 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 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 con ductor causes localized Electric and Magnetic Fields EMF Cutting or gouging current cre ates EMF fields around torch cables and cutting machines ing operations and any other source of heat sparks 8 b EMF fields may interfere wit
42. 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 noz zle 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 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 piercing angle torch about 30 from the plane perpendicular to the work piece transfer the arc then bring the torch perpen dicular to the work and begin parallel move ment 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 inthe plasma arc eroding the orifice of the nozzle tip g Use only Lincoln consumable parts These parts are patented and using any other replac
43. ure they are in tight not dirty tently with repeated trigger pulls or greasy and in good shape Replace if necessary If all recommended possible areas of Make sure the air pressure is set misadjustment have been checked at 65 psi and the problem persists Contact your local Lincoln Authorized Possible fault in Control board Field Service Facility The arc starts but sputters badly Check the torch consumables to be sure they are in tight not dirty or greasy and in good shape Replace if necessary 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 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 LINCOLN 5 TROUBLESHOOTING E 5 Observe all Safety Guidelines detailed throughout this manual Pilot arc starts but will not transfer 1 Check work lead connection for when brought near work clean secure connection Plasma will only cut conductive material Do not attempt to cut fiberglass plastic rubber PVC or any other non conductive material all recommended possible areas of misadjustment have been checked Make sure work piece
44. urse of Action safely contact you local Lincoln Authorized Field Service Facility A WARNING ELECTRIC SHOCK CAN KILL E Turn off machine at the disconnect switch on the front of the machine and remove main power supply connec tions before doing any troubleshooting CAUTION PRO CUT 25 LINCOLN 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 2 TROUBLESHOOTING E 2 Observe all Safety Guidelines detailed throughout this manual is required See Technical Specification page Install a larger input circuit or turn the output control to a lower amperage No Status indicators light and the fan 1 Check the input power to be sure does not operate 5 seconds after the itis on power switch is turned on Check the power line fuses and machine connection Disconnect input power at fuse panel and check line switch conti nuity Replace line switch if bad Check the fuses on the input board If all recommended possible areas of misadjustment have been checked No Status indicators light 5 seconds 1 Disconnect input power from the 8nd the problem persists Contact after the power switch is turned on machine Check that connectors Your local Lincoln Authorized but the fan operates on harness between Control Bd F
45. xplosion Keep flammable material away Do not weld cut or gouge on containers that have held combustibles ARC RAYS can burn e Wear eye ear and body protection PLASMA ARC can injure V p Keep your body away from nozzle and plasma arc Operate the pilot arc with caution The pilot arc is capable of burning the operator others or even piercing safety clothing Observe additional Safety Guidelines detailed in the beginning of this manual DESCRIPTION The PRO CUT 25 is a constant current continuous control plasma cutting power source It provides supe rior and reliable starting characteristics cutting visibili ty 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 regula tor 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 sim ple yet reliable touch start mechanism This system eliminates many of the failure problems associated with hi frequency start systems PREHEAT TEMPERATURE FOR PLASMA CUTTING Preheat temperature
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