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Lincoln Electric PRO-CUT IM637-A User's Manual

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6. Do not weld cut or gouge on contain ers that have held combustibles ARC RAYS B can burn Wear eye ear and body protection PLASMA ARC can injure 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 NOTE All P C boards are protected by a moisture resis tant coating When the plasma cutter is operated this coat ing will bake off of certain power resistors that normally operate at high temperatures emitting some smoke and odor for a short time These resistors and the P C board beneath them may become darkened This is a normal occurrence and does not damage the component or affect the machine performance DESCRIPTION The Pro Cut 55 is a constant current continuous control plasma cutting power source It provides superior and reli able starting characteristics cutting visibility and arc stabili ty When cutting expanded metal the Pro Cut 55 out per forms the competition due to its quick clean response to arc transfers The power supply design provides high transfer to cut distances which makes pierce cutting more reliable and with less nozzle wear 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 d
7. Set the output current control knob at maximum position for high cutting speed and less dross forma tion Reduce the current if desired to reduce the kerf cut width heat affected zone or travel speed as required 2 GAS PRESSURE SETTINGS 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 70 PSI for 25 torch es or 75 PSI for 50 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 3 PREPARING TO CUT 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 This is true unless 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 to improve parts life When the arc is brought within 1 4 from the work piece the arc will transfer the current will ramp up to the setting on the control panel and the cut can last indefinitely or un
8. 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 4 g 4 h Connect the work cable to the work as close to the cutting or 54 5 9 SAFETY 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 gouging area as practical Work cables connected to the build ing fram
9. 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 55 LINCOLN 5 E 6 TROUBLESHOOTING E 6 Observe all Safety Guidelines detailed throughout this manual STATUS BOARD INDICATORS SYMPTOM CHECK Machine is unresponsive immediately after There is a 4 second soft start period for pre charging the input fil power up ter capacitors Wait until that time is up The Power LED will light when ready If not refer to the first part of this section The Air Low 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 70 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 The Safety LED is flashing Make sure there is a Lincoln torch and cable assembly connect ed properly to the Pro Cut bulk head connector Check consumables for proper installation or excessive wear Replace if excessively worn If not use a piece of fine emery cloth to remove any oxide buildup on the tip of the electrode The Safety LED is lit and steady Press the Reset button If torch and consu
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11. This will maximize the performance of the PRO CUT system PRO CUT 55 LINCOLN B 4 LIMITATIONS Do not exceed output current and duty cycle rating of machine Do not use the PRO CUT 55 for pipe thaw ing CONTROLS AND SETTINGS Gas Status Reset Purge Board Button Butt Gas Indicators unon Regulator Gauge K Output Gas Control Regulator Knob Knob Consumable PRO CUT55 Storage behind door E we Input Ba 7 Power Toren W Switch Connector Work Cable When preparing to cut or gouge position the machine as close to the work as possible Make sure you have all materials needed to complete the job and have taken all safety precautions It is important to follow these operating steps each time you use the machine Turn the machine s ON OFF POWER SWITCH to OFF position Connect the air supply to the machine 1 Turn the main power and the machine power switch on The fan should start The pre charge circuit will operate for 4 seconds then the green Power LED should turn on If the SAFETY LED is lit push the Reset but ton If there is no problem the LED will go off If there is a problem refer to Step SAFETY LED in this section If any of the other LED s remain lit and steady refer to the troubleshooting section of the manu al Be sure that the work lead is clamped to the work piece before cutting OPERATION B 4
12. 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 55 LINCOLN 5 E 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 70 psi 75 psi for a 50 ft torch 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 With machine turned off input power removed and torch and consumables connected mea sure resistance on Output Power board between B1 and B21 If gt 10Q possible fault in torch and cable assembly If all recommended possible areas of Possible fault in Output board misadjustment have been checked and the problem persists Contact The air begins to flow and there is very brief arc that snaps out consis be sure they are in tight not dirty Field Service Facility tently with repeated trigger pulls or
13. rating less than or equal to 20 micron would be acceptable to use Inline filter elements will generally filter the air with little restriction to the airflow until the element is about 7596 contaminated After this point there will bea 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 the filter element should be replaced at or before the pressure drop reaches 8 psi Be sure to select a prefilter that will accommodate the necessary flow rating for the PRO CUT as specified in the Installation section of this instruction manual under the Gas Input Connections heading While it is recommended that an inline prefilter be placed ahead of each PRO CUT that may be in stalled in a shared air supply line one large in line prefilter may instead be used to accommodate sev eral PRO CUT s simultaneously If a shared pre is desired it must be rated to provide the necessary flow rate as specified to ensure proper operation of each of the PRO CUT s sharing a connection NOTE When using nitrogen gas from a cylinder the cylinder must have a pressure regulator Maximum psi from nitrogen gas cylinder to PRO CUT 55 regulator should never exceed 150 psi nstall a hose between the nitrogen gas cylinder regulator and the PRO CUT 55 gas inlet A WARNING CYLINDER could explode if dam aged eS Keep
14. 404 LINDUID ATddNS OL M STVNINYAL LO3NNOO 3009 1VOIH103 13 1 001 ANY 3NIHOVIA GNNOXD LNANI 3SVHd LNdNI HLIM LON S3NIHOVW 2 ATddNS OL 50 31 3LIHM 5 0v18 193NNOO 1009 919373 1 OL 193NNOO NOLLVINSNI A009 OL 3dV L LINDUID ATddNS OL L93NNOO 3009 91419313 01 QV31N3389 193NNOO LNANI 3SVHd 9 318V9 HO L OVAOEZ 00c RO 00 ja 202 zoz zoz 103NNOO3M GION310S M ayom ovr 5 L 90 3unss3Hd 6 ss A p lt 206 it VEIT au 826 112 2 4 946 SLT uv K 9 AWVWIHd 78 vH Ame DI Ke 8 007 ZH MOIS ven D I o Hy DEG gema 705 av ser 21 SUV 1082313 99 Jos uiv ger TOYLNOD eme 93130 HOLIMS m oe OS OO
15. Open Circuit Pilot Current Range Voltage MAX 18 Amps 100 Duty Cycle 25 60 Amps 335 REQUIRED GAS FLOW RATE REQUIRED GAS INLET PRESSURE 70 PSI 360 SCFH 80 to 150 PSI 4 8 Bar 10160 LHR 5 4 Bar TO 10 2 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 RECOMMENDED INPUT WIRE AND FUSE SIZES THREE PHASE SINGLE PHASE Type 75 C Type 75 C Type 75 C Copper Type 75 C Copper Fuse Copper Ground Fuse Copper Ground Superlag Wire in Wire in Superlag Wire in Wire in Input or Conduit Conduit Input or Conduit Conduit Voltage Breaker AWG IEC AWG IEC Voltage Breaker AWG IEC AWG IEC Frequency Size Sizes Sizes Frequency Size Sizes Sizes 208 50 60 10 6mm 208 50 60 8 8 4mm 8 8 4mm 230 50 60 10 6mm 230 50 60 8 8 4mm 8 8 4mm 460 50 60 10 6mm 460 50 60 10 mm 8 8 4mm 200 50 60 10 6mm 380 415 50 60 10 6mm 460 50 60 10 6mm 575 50 60 10 6mm PHYSICAL DIMENSIONS Weight Including Machine Torch and Torch Cable Length 25f 7 6m 50ft 15 2m 70 lbs 85 Ibs 32 kg 39 kg 1 Input volt t be within 10 of rated value 1 Input voltage must be within 10 of rated value LINCOLN A 2 INSTALLATION A 2 SAFETY PRECAUTIONS Read entire Installation Section before installing the PRO CUT 55 A WARNING ELECTRIC SHOCK CAN KILL Only
16. design for industrial use Continuous control 25 60 amps Reliable touch start mechanism for plasma arc initi ation Unique microprocessor controlled starting sequence for safe and consistent starting Rapid arc transfer for fast cutting of expanded metal High transfer distance for ease of use Soft start of input filter capacitors at start up OPERATION Input over voltage protection Bright 3 0 second timed pilot arc Purge momentary push button Air regulator and pressure gage located on the front of machine for convenience Parts in Place mechanism to detect proper installa tion of consumables and torch Latching Parts in Place mechanism Requires a positive operator reset Automatic detection of faulty output control In line coarse air filter Preflow Postflow timing Preflow is eliminated if arc is re initiated in Postflow Thermostatic Protection Solid state over current protection Works with pure nitrogen for cutting nonferrous materials Reconnectable for multiple input voltages Quick disconnect torch 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 Unique drag cup design for durability and elimina tion of double arcing PRO CUT 55 LINCOLN ES OPERATION B 3 CUTTING CAPABILITY The PRO CUT 55 is rate
17. 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 55 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 flow rate and equipment may produce results different than those expected Some adjustments to procedures may be necessary to compensate for unique individ ual conditions Test all procedures duplicating actual field conditions RECOMMENDED PROCESSES AND EQUIPMENT The PRO CUT 55 is capable of all cutting and goug ing applications within its output capacity of 25 to 60 amps These applications include thin gage sheet metal and expanded metal OPERATIONAL FEATURES AND CONTROLS The PRO CUT 55 comes with an ON OFF POWER SWITCH OUTPUT CURRENT CONTROL PURGE BUTTON and a SAFETY RESET BUTTON DESIGN FEATURES AND ADVANTAGES The microprocessor controlled PRO CUT 55 design makes plasma cutting and gouging tasks uncomplicat ed 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 Light weight and portable
18. greasy and in good shape Replace if necessary Make sure the air pressure is set at 70 psi 75 psi for a 50 ft torch Possible fault in Output Power board 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 70 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 55 LINCOLN 5 E 5 TROUBLESHOOTING E 5 Observe all Safety Guidelines detailed throughout this manual Pilot arc starts but will not transfer 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 Make sure work piece is clean and dry Remove any scale rust or dross Check all connections to Output If all recommended possible areas of board misadjustment have been checked and the problem persists Contact Possible faulty Control board your local Lincoln Authorized
19. 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 Tilt the torch about 45 from the workpiece and hold the nozzle 1 8 3 2mm to 3 16 4 7mm above the workpiece for gouging Clean spatter and scale from the nozzle and drag cup frequently ANGLE OF APPROACH Ke HELD AT 2 45 ANGLE THROUGHOUT GOUGE E MAINTAINED THROUGHOUT 1 SAFETY LED e If the SAFETY LED lights at any time check the following WARNING ES ELECTRIC SHOCK CAN KILL Turn off machine the disconnect switch on the front of the machine before tightening cleaning or replacing consumables 2 IN NORMAL OPERATION THE SAFETY LED MAY TEMPORARILY ILLUMINATE AND CLEAR ITSELF AUTOMATICALLY WITH OUT DEPRESSING THE RESET BUTTON 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 cr
20. manual 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 Auxiliary transformer may be faulty No Status indicators light 5 seconds 1 Auxiliary transformer may be after the power switch is turned on faulty but the fan operates Disconnect input power from the machine Check that connectors on harness between Control Bd and Display Bd are properly seat If all recommended possible areas of misadjustment have been checked Possible faulty Control Board and the problem persists Contact your local Lincoln Authorized Field Service Facility All Status indicators remain lit imme 1 The microprocessor has experi diately after power up enced a memory fault Consult local Lincoln Field Service shop All Status indicators begin to blink 1 Turn power off Make sure recon within 5 seconds after power up nect is positioned correctly for the input voltage used Wait at least 1 minute after power down before re connecting the machine Reconnect machine then restore power to Pro Cut Possible faulty Primary board Possible faulty Control board CAUTION If for any reason you do not understand the test procedures or are unable to perform the te
21. removidas SER HGTBI BUSUR RE ERE e 430 wel Me z WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO BIR Chinese oe lue chal TAU Gall d arin Mall oe Quad us by pha NM uu 0 juil e AREY cuts UI ai Y e Aale veel Al dl LEIA COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO SIGA AS PRATICAS DE SEGURANCA DO EMPREGADOR SBM BHO X HD OHBRBEE lt K EL TRHOKRERE HAM ERU Rr de t D LR fb FB B o 0 Al Soll AIXAM SALAD HAY zeit TAS PSP HHCH veel dl illai aut Jud al ply Gail ag ls L LINCOLN 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
22. 0 psi Pressure guage located on the front of the machine should be set to approximately 70 PSI for a 25 ft torch and 75 PSI for a 50 ft torch while gas is flowing purging or cutting Flow rate should be approximately 6 0 cfm 170 I min NOTE Oil in the air supply to the PRO CUT 55 can cause severe problems Use only a clean air supply Connect the gas supply to the PRO CUT 55 regula tor Compressed gas should be supplied to the fitting connection mounted on the filter at the rear of the machine If necessary this fitting can be removed allowing plumbing access through the 1 4 NPT input port on the filter body If compressed air is being used it is highly recom mended that an inline prefilter be installed in the air supply line ahead of the air connection to the PRO CUT S coalescing filter While the coalescing filter is used to remove small amounts of oil and water aerosol particales from the air supply line the pre filler can be used to remove larger particulates before they reach the coalescing filter element This will prolong the life of the coalescing filter element by up to six times what it would be without the prefilter and in turn prolong the life of the PRO CUT torch and consumables as well A standard nominal 5 micron inline prefilter is rec ommended however for optimum performance select a prefilter with a micron absoluterating If these filter ratings are unavailable anything with a
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24. 9V1L10A NOLLO3NNOO 21VIHdOHddY NO 3309 NOWWOO V 9NIAVH HO SIN3NOdWOO MOHS LON AVI WV3OVIG SIHL 313 4WO9 V 40 1 IHL SNILO333V LNOHLIM 39NVHO AVIA QHVOS V 30 SIN3NOdWOO SONIS LIN9HI9 J3ALLO31OHd ANOHA 3SVO dsva 1 1 ATddNS OL AS A N SIVNINHAL LOANNOO 763002 1V91419313 17 201 TVNOLLVN Yad 3NIHOVIA 3SVHd 22001 319V9 1ndNI HLIM LON SANIHOWW 304 2 ATddNS OL SQV313 IHM 510v 18 LO3NNOO SNIHOVW 30 1331 OVAO9T Ov 11 1991 b 2 1 IC LEZ Jos HV L REP Ser vive U D oom zi oH SH oa Mus E 0 056 Ku 105 091895 OWASLS 099 b Y lt C 90 3unssauid NU lt lt 206 55 D ulv MOTS YIDAL Zr bS 5 eer Hoy A ON Ave EZ 9er D I
25. A Standard W117 2 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS 1 e 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 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 When cutting or gouging in damp locations on 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 9 1 h safe operating condition Replace damaged insulation Never dip the torch in water for cooling or plasma cut or gouge in or under water When working above floor level protect yourself from a fall should you get a
26. IM637 A PRO CUT 55 For use with machines having Code Numbers 10571 10572 10475 10476 10586 and 10587 11011 11012 11013 11014 11015 and 11016 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 to 180 9001 Heq rementa LINCOLN D CERTIFICATE NUMBER 30273 LI N CO LN Copyright 2005 Lincoln Global Inc 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 SAFETY i 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 ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CS
27. INSULATED PLIERS INSULATED GLOVES PRO CUT 55 LINCOLN 5 D 2 MAINTENANCE D 2 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 Power Output and Control printed circuit boards and heat sinks Power switch Main Transformer Input Rectifier 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 Check the air regulator filter to be sure it does not become clogged The air filter on the machine is self draining and will not have to be emptied 5 Check the filter element every several months to see if it is clogged weekly in very dirty environ ments Replace if necessary by first removing the two screws that attach the filter cage to the back panel assembly then slide the cage away from the back of the machine and remove Next twist the clear filter bowl until it comes off be careful not to lo
28. T ELECTRICAL CONNECTIONS Before installing the machine check that input supply voltage phase and frequency are the same as the machine s voltage phase and frequency as specified on the machine s rating plate The Pro Cut 55 should be connected only by a quali fied electrician Installation should be made in accor dance with all local and national codes eg U S National Electrical Code and the information detailed below SINGLE PHASE INPUT CONNECTION FOR 208 230 460 VOLT MACHINES The 208 230 460 Volt Pro Cut 55 is supplied with one 11 ft 48 AWG 3 conductor input power cord with a molded 230 VAC plug on one end already connected to the machine When received from the factory this machine is internally connected for 230 VAC Re con nection will be necessary if a higher or lower input voltage is used CONVERTING A 208 230 460 VOLT MACHINE FROM SINGLE PHASE TO THREE PHASE INPUT To convert to three phase power the 230 VAC 3 con ductor power cord must be removed and replaced with a 10 AWG 4 conductor power cord 1 Connect the green lead to ground per U S National Electrical Code 2 Connect black red and white leads to power THREE PHASE POWER INPUT CONNEC TION FOR 200 380 415 VOLT amp 460 575 VOLT MACHINES The 200 380 415 Volt and 460 575 Volt Pro Cut 55 s are supplied with one 10 ft 10 AWG 4 conductor input power cord already connected to the machine When received from the factory these machines are
29. ater like appearance replace it along with the nozzle The maximum wear depth of the electrode is approximately 060 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 f the machine does not reset or continues to trip consult the Troubleshooting Section Use the proper cutting or gouging procedures referred to in Procedure Recommendations PRO CUT 55 LINCOLN B 6 OPERATION B 6 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 PROCEDURE RECOMMENDATIONS When properly used plasma arc cutting or gouging is a very economical process Improper use will re
30. 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 LINCOLN 5 NOTES LINCOLN 5 SAFETY PR CAUTIONS DE S RET 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 6 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 Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment
31. 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 2 Dans le cas de travail au dessus du niveau du sol se prot ger PR CAUTIONS DE S RET POUR contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie LES MACHINES SOUDER TRANSFORMATEUR Un coup d arc peut tre plus s v re qu un coup de soliel REDRESSEUR donc a Utiliser un bon masque avec un verre filtrant appropri 1 ainsi qu un verre blanc afin de se prot ger les yeux du ray 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 Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans
32. ched off and the fan prob lem or air obstruction must be corrected 2 Filter Capacitor Conditioning Pro Cut 55 400 460 or 460 575 VAC only A protection circuit is included to monitor the voltage across filter capacitors C1 and C2 In the event that the capacitor voltage is too high the protection circuit will prevent output The protection circuit may prevent output providing all these circumstances are met a Machine is connected for 400 460 or 460 575 VAC input b Machine did not have power applied for many months c Machine will not produce output when power is first switched on If these circumstances apply the proper action is to switch the machine on and let it idle for up to 30 min utes This is required to condition the filter capacitors after an extended storage time The protection circuit will automatically reset once the capacitor conditioning and resultant voltage levels are acceptable It may be necessary to turn the power switch off and back on again after this period PRO CUT 55 LINCOLN 5 E 1 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 thro
33. cylinder upright and 7 chained to a fixed support Keep cylinder away from areas where it could be damaged Never lift machine with cylinder attached Never allow the cutting torch to touch the cylin der Keep cylinder away from live electrical parts Maximum inlet pressure 150 psi OUTPUT CONNECTIONS Torch Connection The Pro Cut 55 is sent from the factory with a PCT 80 cutting torch Additional cutting torches can be ordered from the K1571 series Hand held and mech anized torches come with 25 or 50 cables All torches are connected to the Pro Cut with a quick connect on the casefront for easy change over This feature is excellent for changing between a hand cut ting torch and a mechanized torch For more information on the torch and its components refer to the PCT80 Operators Manual IM588 latest version PRO CUT 55 LINCOLN 5 B 1 OPERATION B 1 SAFETY PRECAUTIONS Read and understand this entire section before oper ating the machine A WARNING e 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 23 can be dangerous S Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone WELDING CUTTING and GOUGING SPARKS can cause fire or explosion Keep flammable material away
34. d at 55 amps at 50 duty cycle on a 10 minute basis runs 55 amps for 5 minutes then idling for 5 minutes or 40 amps at 100 duty cycle continuous use 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 55 when cutting mild steel The graph plots cut thickness vs torch travel speed with a torch standoff of 0 15 Example 0 25 material may be cut at a setting of 35 amps at an approximate speed of 38 IPM or at a setting of 45 amps at an approximate speed of 57 IPM or at a setting of 55 amps at an approximate speed of 62 IPM Lincoln s PRO CUT 55 Mild Steel Cut Capacity Chart 100 60 Recommended Torch Travel Speed IPM 80 of Maximum Speed 20 55A 0 0 000 0 125 0 250 0 375 0 500 0 625 0 750 Material Thickness Figure B 1 CONSUMABLE LIFE The expected life for the Pro Cut 55 s electrode under normal operating conditions is approximately 50 to 60 min utes of cutting time at the machine s maximum rated output An erosion of approximately 060 in the electrode tip is typi cal for the end of electrode life however the electrode may last longer A sustained green and erratic arc will indicate definite electrode failure and both the electrode and nozzle should be replaced immediately It is recommended that consumables electrode and nozzle be replaced in complete sets
35. 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 Where possible start the cut from the edge of the work piece Keep moving A steady speed is necessary Do not pause Do not allow torch cable or body to contact hot surface PRO CUT 55 LINCOLN B 7 OPERATION B 7 Suggestions for Extra Utility from PRO CUT System the 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 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 noz zle turn on the power and continue cutting If the Parts in Place circuit continues to trip after clean ing the consumables then replace them with a new set Do not continue to try and cut with exces sively worn consumables as this can cause dam age to the torch head and will degrade cut quality To improve consumable life here are some sug gestions that may be useful a Never drag the nozzle on the work surface if the o
36. ework 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 Oylinders 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 Never allow any part of the electrode torch or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylin ders associated equipment and CGA publication Precautions for Safe Handling of Compressed Gases in Oylinders available from the Compressed Gas Association 1235 Jef
37. f needed replace air filter and check change air supply For more information refer to the Gas Input Connections section in the manu al 4 Make sure there is a Lincoln PCT 80 torch connected properly to the Pro Cut 55 and that the consumables are properly installed Make sure the shield cup is hand tight Do not use pliers or over tighten After verifying that the torch and consumables are properly set in place NOTE Make sure that consumables are Lincoln Electric brand consumable parts These parts are patented and using any other replacement consumables may cause damage to the torch or reduce cut quality Also be sure to check that the nozzle is the correct part number as identified on the top and side of the nozzle for the Pro Cut being used If problems still persists after completing steps 1 thru 4 contact your local Lincoln Authorized Field Service Facility PRO CUT 55 LINCOLN 5 Jequunu epoo 1ueuudinbe y e jueunredeg eui si eui j sjeued y JO euo uo y LL paysed s epoo e 104 jenueui Aq je 104 eq jou 104 51 SIUL 601 10000 81 8 40 301S 1N3NOd OO INGIA 16913 H3d SIOSWAS 1V2IH10313
38. ferson 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 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 con ductor causes localized Electric and Magnetic Fields EMF Cutting or gouging current cre ates EMF fields around torch cables and cutting machines 8 b EMF fields may interfere with some pacemakers so opera tors 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
39. ff of the ground screw assembly 8 Loosen the cable connector on the case back 9 Pull the line cord out of the machine carefully feed ing it under the aluminum bracket as you pull CORD INSTALLATION 1 Feed the new cord through the cable connector and into the machine carefully feeding it under the aluminum bracket PRO CUT 55 LINCOLN 5 A 4 INSTALLATION A 4 2 If the ground screw assembly is loose tighten the assembly to the base before installing the new ground lead Install the green lead on the ground screw assembly replace the plain washer and lock washer then tighten nut Install in accordance with all local and national electrical codes 3 Connect the new cord to the switch observing the color code on the wiring diagram 4 Angle the line switch so the screws on the switch can be tightened Comply with the torque rating stamped on the switch 5 Feed the line switch back into case front 6 Replace the two screws that hold the line switch on to the case front 7 Tighten the cable connector on the case back 8 Replace wraparound and tighten the eleven screws on the case sides and top 9 Connect the new input power cord to a fused three phase power supply Make sure the green lead is connected to the panel and the panel is connected to a good earth ground Install in accordance with all local and national electric codes NOTE Fusing requirements of the machine input will change depending on whether
40. internally connected for the higher input voltage Re connection will be necessary if a lower input voltage is used CONVERTING 200 380 415 VOLT amp 460 575 VOLT MACHINES FROM THREE PHASE TO SINGLE PHASE INPUT To convert to single phase power the 4 conductor input cord may still be used but the red lead must be disconnected and insulated 1 Connect the green lead to ground per U S National Electrical Code 2 Connect black and white leads to power 3 Wrap red lead with tape to provide 600V insulation INPUT POWER CORD CONNECTOR INSTALLATION A cord connector provides a strain relief for the input power cord as it passes through the left rear access hole The cord connector is designed for a cord diam eter of 40 1 08 in 10 2 26 2mm if it becomes nec essary to install a different input cord CORD REMOVAL 1 Unplug line cord from the receptacle A WARNING NOTE DO NOT PERFORM THE NEXT STEP UNTIL THE HIGH VOLTAGES INSIDE THE MACHINE HAVE BEEN ALLOWED TO DISSIPATE APPROXI MATELY TWO MINUTES 2 Remove wraparound by unscrewing the eleven Screws on the case sides and top 3 Unscrew the two screws that hold the line switch onto the case front 4 Pull the line switch out of the case front 5 Angle the line switch so the screws on the near side of the switch can be loosened 6 Loosen the screws and remove the existing cord from the switch 7 Remove the nut lock washer plain washer and green lead o
41. ip of the electrode or try replacing the electrode and nozzle Try to recount the number of times that the Safety LED has come on lit and steady with this particular set of consumables If problems persist after completing steps 1 and 2 contact your local Lincoln Authorized Field Service Facility B If the Safety LED is FLASHING perform the following 1 Check the condition of the electrode The maximum wear depth in the center of the electrode tip is approxi mately 060 relative to the surrounding tip A green and erratic arc will indicate definite electrode failure as explained in the Consumable Life section of this manual Replace both electrode and nozzle if electrode is excessively worn Otherwise use a piece of fine emery cloth to remove any oxide buildup on the tip of the electrode Even if consumables appear to be in good working order it is possible that they are the cause of the problem Try replacing 2 Check the conditions of the inside of the nozzle Make sure that both the electrode and nozzle are not dirty oily or corroded e f debris has collected rub the electrode on the inside bottom of the nozzle to remove any oxide layer that may have built up If problems persist try replacing consumables 3 Remove consumables from torch and check inside of torch head for contamination Check incoming airflow for contaminants f torch head is contaminated take a dry cotton swab and clean out the pollutants I
42. l aa CEN 8 2 09 01 PRO CUT 55 LINCOLN NOTES PRO CUT 55 LINCOLN 5 NOTES PRO CUT 55 LINCOLN 5 WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO Japanese ER BIR Korean Do nottouch 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 moja a Aislese del trabajo y de la 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 mit Ihrem oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden e toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da pega e terra RABE ELE 6 OMLMPT APSSAPREBS NTUSHILT FSU e E GUB DERNIERE GH Oa CRM ER Xe uc a Sal e sis Weal AMI W uil el all Quali Y O 1 gl o as lala AA ll DA dan Y Jio wae Keep flammable materials away e Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entferne
43. les zones l on pique le laitier LINCOLN 5 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 V V for selecting a QUALITY product by Lincoln Electric We want you Thank You to 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 Purchased Whenever you request replacement parts or information on this equipment always supply the informatio
44. 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 Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie 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 galvanis 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
45. mables are properly installed the Safety LED should turn off Normal cutting or goug ing can resume The Thermal LED is lit 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 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 Possible faulty Control board The Ready Air Low and Thermal LED s This is typically caused by connecting the auxiliary transformer input tap to the wrong voltage Turn machine OFF and change lead to correct input voltage at reconnect panel are flashing Possible faulty Control P C Board PRO CUT 55 LINCOLN 5 E 7 TROUBLESHOOTING E 7 Observe all Safety Guidelines detailed throughout this manual CONSUMABLE RELATED SAFETY LED TROUBLESHOOTING A If the Safety LED is LIT AND STEADY perform the following 1 If the reset button when pressed does not turn the Safety LED off the reset button or associated wiring may be faulty See the wiring diagram Press the reset button If the torch and consumables are properly installed the Safety LED should turn off 2 If this has occurred numerous times clean consumables with a piece of fine emery cloth to remove any oxide buildup on the t
46. match its performance N GENERAL OPTIONS ACCESSORIES The following options accessories are available for your PRO CUT 55 from your local Lincoln Distributor K1600 1 Undercarriage A valet style undercarriage with pull out handle for machine only Provides Torch and Work Cable storage 22147 043 VORTECH nozzle with an 043 1 2 mm Orifice 22147 068 VORTECH nozzle with an 068 1 7 mm Orifice 22149 Electrode replacement electrodes for cut ting 22150 Shield Cup This shields the torch tip and provides more visibility to the workpiece than the drag cup Note The shield cup does not prevent the torch tip from touching the workpiece 522151 Drag Cup The drag cup protects the torch by preventing the torch from touching the workpiece K1571 Series PCT 80 Torches come in 25 and 50 lengths in either hand held or mechanized versions K1678 1 MACHINE INTERFACE KIT This kit is compatible with the present models of the Pro Cut 55 Machines having code numbers 10473 and 10474 may require their Output PC Board to be upgraded to a G3326 2 board This kit provides the necessary hardware and instruc tions to install a14 Pin MS Type remote connector into the machine This connector provides provisions for the following interface signals between the Pro Cut 55 and the controller ARC START The Arc Start circuit allows for triggering of the power source to commence cutting This circ
47. n Sie brennbarres Material Mantenha inflamaveis bem guarda dos MMIC LU THEW EKA 9 Vi S BET freA eis Ad d s Jo Aal a88 Ad AIX ole 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 A HRUSHICRBRELTE EU OMAR HRSRSORENE ez 119 59 dis 4 Lilly lan EE 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 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 la zona de res piraci n e Mantenga la cabeza fuera de los humos Utilice
48. n 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 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 M Section A Technical Specifications us A 1 Safety EE A 2 Select Proper Location sisi A 2 Sucre E A 2 Lifting and Moving sise A 2 Eg EE A 2 High Frequency Interference Protection ese A 2 Input Electrical Connecti
49. of Metal B 6 Suggestions for Extra Utility from the PRO CUT System B 7 5 1 5 e Section C Genuine Lincoln C 1 General Options ACcessorles ener enne nnne nenas C 1 vii TABLE OF CONTENTS Page Maintenance tuc ec dc xxx AE Section D Safety Precautions isinna in ne sen D 1 Input Filter Capacitor Discharge D 1 Bella D 2 EE D 2 Troubleshooting ss A Section E Safety e M E 1 How to Use Troubleshooting Guide nen E 1 Troubleshooting EI E 2 Wiring Diagrams 1 nnmnnn nannan naa Section F WINING NAG AN ee F 1 thru F 4 DIMENSION 5 Parts LISE EEN P309 Series amp P210 K vii INSTALLATION ad TECHNICAL SPECIFICATIONS PRO CUT 55 THREE PHASE SINGLE PHASE Standard Input Current Standard Input Current Voltage at Rated Output Model Voltage at Rated Output Model 208 230 460 31 28 17 50 60 Hz 208 230 460 60 55 30 50 60Hz 200 380 415 30 17 16 50 60 Hz 460 575 17 14 50 60 Hz RATED OUTPUT Duty Cycle AMPS 50 Duty Cycle 55 100 Duty Cycle 40 OUTPUT Current
50. ons eats ceased a A 3 Power Input Connection for 208 230 460 Volt A 3 Power Input Connection for 200 380 415 Volt Machines A 3 Input Power Cord Connector Installation A 3 saisine mini a E E i A 3 Cord Installation ss A 3 Frame eire A 4 Input Voltage Reconnection A 4 Use on Engine Driven Power A 4 Gas Input Connections 5 leg EE A 5 Torch COnMe tion sise A 5 eC Section B Safety Precautions cuite ede enl codcm ed B 1 Bro td B 1 Preheat Temperature for Plasma Cutting B 1 User Responsibility sen B 2 Recommended Processes and B 2 Operational Features and B 2 Design Features and Advantages B 2 Cutting B 3 Consumable Life troi anime e E a ees B 3 Bude ET B 4 Controls and Settings B 4 B 5 Pilot Arc DISCUSSION m B 6 Procedure B 6 Generali encor nbus trot tu B 6 Thin Sheet Metal irent ice o od beer B 6 Thick Sections
51. qualified personnel should install this machine e Turn the input power OFF at the disconnect switch or fuse box and discharge input capacitors before working inside the equip ment not touch electrically hot parts e Always connect the PRO CUT 55 ground ing terminal located on the side of the Case Back Assembly to a good electrical earth ground e Turn the PRO CUT Power Switch OFF when connecting power cord to input power SELECT PROPER LOCATION Place the Pro Cut 55 where clean cool air can freely circulate in through the rear louvers and out through the front bottom opening Dirt dust or any foreign material that can be drawn into the machine should be kept at a minimum Failure to observe these precau tions 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 55 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 6 0 cfm 170 Failure to observe these pre cautions could result in excessive operating tempera tures or damage to the torch STACKING The PRO CUT 55 cannot be stacked LIFTING AND MOVING Either the front or rear handles or both may be used to lift or move the machine DO NOT use the pull handle on the optional undercar riage if installed to lift the machine This handle is no
52. rictions The Pro Cut 55 can be operated on engine driven generators as long as the engine drive output meets the following conditions The AC wave form frequency is between 45 and 65 Hz For 200 230 VAC Supplies The AC wave form peak voltage must be below 420 volts The RMS voltage must be 230VAC 15 The 230 VAC auxiliaries of Lincoln engine drives meet these conditions when run in the high idle mode For 380 415 VAC Supplies The AC wave form peak voltage must be below 840 volts The RMS voltage must be 400 VAC 10 For 460 VAC Supplies The AC wave form peak voltage must be below 840 volts The RMS voltage of the AC wave form must be 460 VAC 10 Input Power Restrictions The available output current of the Pro Cut 55 may be limited due to the output capacity of the engine driven power supply The following are recommended output current settings when used with various Lincoln engine driven power supplies Engine Drive Auxiliary Power Pro Cut 55 Output 8KW 30 Amps 9KW 40 Amps 8KW 30 Amps 8 5KW 35 Amps 9KW 40 Amps 12KW 55 Amps 40Amps 40Amps 45 Amps 45 Amps 55 Amps 55 Amps 9 5KW 9 5KW 10KW 10KW 12KW 12KW RANGER 305D COMMANDER 300 COMMANDER 400 COMMANDER 500 VANTAGE 500 PRO CUT 55 LINCOLN 5 5 INSTALLATION A 5 GAS INPUT CONNECTIONS Supply the PRO CUT 55 with clean compressed air or nitrogen Supply pressure must be between 80 psi and 15
53. se the o ring seated at the top of the bowl threads Unscrew the filter element and replace with new element Assemble parts in reverse order as described above 6 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 1 Thermal Protection Two thermostats 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 thermostat will prevent output voltage or current Thermostats 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 swit
54. 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 6 ARC RAYS can burn 2 a Use safety glasses and a shield with the prop 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 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 head out of the fumes Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing
55. sts repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed PRO CUT 55 LINCOLN 5 E 3 TROUBLESHOOTING E 3 Observe all Safety Guidelines detailed throughout this manual 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 Auxiliary transformer may be faulty The main gas solenoid assem bly may be faulty Check or replace Possible faulty Output Power board d Possible faulty Control board check for continuity from the bulk head connector to the molex See Wiring Diagram 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 If all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Lincoln Authorized Field Service Facility Check for proper trigger switch operation Remove the torch cable assembly from the Pro Cut and test for continuity between 9 and 1 at the quick connect when the trig ger switch is depressed and no continuity when the switch is not depressed Replace the trigger Switch or torch cable if defective Possible faulty Control board Possible faulty Output Power
56. sult in a very high operating cost General In All Cases Follow safety precautions as printed throughout this operating manual and on the machine Thin Gauge Sheet Metal Torch Standoff Machine Output Setting _ DRAG thru 1 16 Standoff Output Setting Min Range thru 45 Amps 1 Output set below 45 amps The nozzle may be dragged on the metal sur face touching it lightly to the surface after pierc ing a hole Current control should be set below the mid range 2 Current Control should be set below the mid range Do not allow cable or body to contact hot sur face Thick Sections of Metal Torch Standoff Machine Output Setting 45 1 8 thru 3 16 Standoff Output Setting 45 Amps thru Max Range 1 Output set above 45 amps The best quality and consumable life will be obtained by holding the torch off the surface about 3 16 Too long an arc may compromise cut quality and consumable life The nozzle should NOT be dragged on the work 2 The nozzle should not be dragged on the work surface Dragging the nozzle on the work surface will result in shortened consumable life Use of the S22151 Drag Cup will maintain the proper standoff and eliminate nozzle double arcing 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
57. t designed to support the full weight of the machine and using it to lift the machine could cause personal injury or damage to the machine TILTING The PRO CUT 55 must be placed on a stable level surface so it will not topple over HIGH FREQUENCY INTERFERENCE PROTECTION The Pro Cut 55 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 ground clamp isolated from other work clamps that have high frequency 3 lt If the ground 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 PRO CUT 55 LINCOLN 5 A 3 INSTALLATION A 3 INPU
58. the machine is used on single phase or three phase Use the chart in the TECHNICAL SPECIFICATIONS to change the fuses to the proper value FRAME GROUNDING The frame of the Pro Cut 55 must be properly ground ed A ground terminal marked is mounted on the case bottom directly behind the input power switch for this purpose The cable that is sent attached to the machine is connected to this ground terminal See the National Electric Code for details on proper grounding methods Install in accordance with all local and national electrical codes INPUT VOLTAGE RECONNECTION PROCEDURE When changing input voltages it is necessary to change the settings behind the access door on the side of the machine A WARNING Failure to do so may result in damage to the machine To reconnect the Pro Cut follow the directions as out lined below Follow this procedure ONLY while the Pro Cut is disconnected from the input power and the capacitors have properly discharged 1 Open the access door on the side of the machine 2 For 200 to 230 Position the large switch to 200 230 For 400 to 460 Position the large switch to 400 460 For 550 to 575 Position the large switch to 550 575 3 Move the A lead to the appropriate terminal USE ON ENGINE DRIVEN POWER SUPPLIES The Pro Cut 55 can be used on engine driven power supplies However the following AC Wave Form Voltage and Input Power Restrictions do apply AC Wave Form Rest
59. til the duty cycle of the Pro Cut is exceeded Do not touch the nozzle to the work when cutting with the control panel setting above 45 amps or damage to the consumables will result 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 PRO CUT 55 LINCOLN B 5 OPERATION B 5 Hold the nozzle standoff 1 8 3 2mm to 3 16 4 7mm above the workpiece during cutting Do not let the torch nozzle touch the work or carry a long arc 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 5 15 Leading Angle gt Direction of Travel hx d H 10 20 Arc Lag Use a 5 15 leading angle in the direction of the cut Use the drag cup to maintain constant standoff for better cut quality and to protect the nozzle from spat ter Use the drag cup with a metal template to prevent nozzle double arcing 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
60. tor and connect resistor leads across the two capacitor terminals Hold resistor in place for 10 seconds DO NOT TOUCH CAPACITOR TERMINALS WITH YOUR BARE HANDS 2 Remove the 5 16 hex head screws from the side and top of the machine and remove wrap around machine cover 3 Be careful not to make contact with the capacitor terminals that are located on the top and bottom of the Power Board on the right side of the machine 7 Repeat discharge procedure for the other capaci tor 8 Check voltage across terminals of all capacitors with a DC voltmeter Polarity of capacitor terminals is marked on PC board above terminals Voltage should be zero If any voltage remains repeat this capacitor discharge procedure FIGURE D 1 LOCATION OF INPUT FILTER CAPACITOR TERMINALS A 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 4 Obtain a high resistance and high wattage resistor 25 1000 ohms and 25 watts minimum This resis tor is not supplied with machine NEVER USE A SHORTING STRAP FOR THIS PROCEDURE tric shock POWER UPPER BOARD CAPACITOR TERMINALS 4 LOWER CAPACITOR TERMINALS POWER RESISTOR RIGHT SIDE OF MACHINE
61. ue to the high voltages involved The Pro Cut 55 comes standard with an air regulator coarse air filter and pressure gauge There are six different torch and cable systems to choose from hand held torch with 25 or 50 cable machine and robotic torch both with 25 and 50 cable Consumables are included so that cutting can begin right out of the box Consumables can also be ordered as individual packages The Pro Cut 55 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 The Pro Cut 55 is capable of cutting with nitrogen or air The Pro Cut 55 is controlled by a microprocessor based control board The machine performs rudimentary self trou bleshooting when powered up which aids in field servicing PREHEAT TEMPERATURE FOR PLASMA CUTTING Preheat temperature control is not necessary in most appli cations when plasma arc cutting or gouging Preheat tem perature 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 tem perature is recommended as a starting point Higher tem peratures may be used as required by the job conditions and or prevailing codes If cracking or excessive hardness occurs on the cut
62. ughout 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 SYMP TOMS 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 Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service Facility A WARNING ELECTRIC SHOCK CAN KILL _ 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 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 LINCOLN 5 E 2 TROUBLESHOOTING E 2 Observe all Safety Guidelines detailed throughout this
63. uit can be accessed through pins K and M of the 14 pin MS con nector The circuit has a 17 VDC nominal open circuit voltage and requires a dry contact closure to activate ARC INITIATED The Arc Initiated circuit provides information as to when a cutting arc has transferred to the work piece This circuit can be accessed through pins and J of the 14 pin MS connector The circuit provides a dry contact closure when the arc has transferred Input to this circuit should be limited to 0 3 A for either 120VAC or 30VDC ARC VOLTAGE The Arc Voltage circuit can be used for activating a torch height control This circuit can be accessed through pins D and G of the 14 pin MS connector The circuit provides full electrode to work arc voltage no voltage divider 335VDC maximum Arc Start K 2A D 344 8 343 uu Arc Voltage 14 PIN BOX RECEPTACLE FRONT VIEW J 347 Arc Initiated Users wishing to utilize the Machine Interface can order a K867 Universal Adapter please adhere to the pin locations stated above or manufacture a 14 pin MS connector cable assembly PRO CUT 55 LINCOLN 5 D 1 MAINTENANCE D 1 INPUT FILTER CAPACITOR 5 Locate the two capacitor terminals large hex head DISCHARGE PROCEDURE cap screws on the top and bottom of the Power P C Board shown in Figure D 1 1 Turn off input power or disconnect input power lines 6 Use electrically insulated gloves and insulated pli ers Hold body of the resis
64. utput control knob is above 45 amps b Make sure the air supply to the Pro Cut is clean and free of oil Use several extra in line filters if necessary c Use the lowest output setting possible to make a good quality cut at the desired cut speed d Minimize dross buildup on the nozzle tip by starting the cut from the edge of the plate when possible e 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 perpen dicular to the work and begin parallel move ment f Reduce the number of pilot arc starts without transferring to the work g Reduce the pilot arc time before transferring to the work h Set air pressure to recommended setting A PRO CUT 55 LINCOLN higher or lower pressure will cause turbulence in the plasma arc eroding the orifice of the nozzle tip i 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 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 55 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
65. ventilaci n o aspiraci n para gases e 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 f r gute Be und Entl ftung des Arbeitsplatzes e Mantenha seu rosto da fumaca Use ventilac o e exhaust o para remover fumo da zona respirat ria eti ADP5o5UtRcocuc 9 fsUPBHEILTASESUCFEU e Fat ie ER SH7IAE else e SUAS MAS AH PARAH 587E MBH 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 avant 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 X7TTLA UAVCRUD PRE gt DF e His BIS ER 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 e Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes opere com 05 paineis abertos ou guardas
66. 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 sparks and hot materials from plasma cutting or gouging can easily go through small cracks and openings to adjacent areas

Lincoln Electric PRO-CUT IM637-A User's Manual

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