Lincoln Electric IM10006 User's Manual
Contents
1. e i 9 8 io erla SUR ug Am s nisu ALD st yt rap 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 e Tragen Sie Augen Ohren und K r perschutz Use prote o para a vista ouvido e corpo BH HRUHHERMRELTTF e QRERR HERHSEGSRHR ec 49 Sol y due Lily c jui s READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES 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 ventilaci n o aspiraci n para gases Gardez la t te l cart des fum es Utili2. B 5 MAINTENANCE ED Section D Safety de e ET D 1 Routine Mammtenance sise D 1 P rodic GE Wunne D 1 Compressed Air Filter sine D 2 Troubleshooting E Section E Safety e EE E 1 How to Use Troubleshooting Guide E 1 Troubleshooting Guide neret E 2 Wiring Diagrams ss nnne nnn nante nnn Section F WY MUA VAG ciet F 1 Parts LISIS 1 n ideo EE P 607Series vi A 1 INSTALLATION AP TECHNICAL SPECIFICATIONS PLASMA 20 INPUT SINGLE PHASE Standard Voltage 19 Input Current at Rated Output 115 1 50 60Hz 15 Amp Branch 115 V 20A 50 115 1 50 60Hz 20 Amp Branch with 20 Amp Plug 115 V 26A 40 RATED OUTPUT 5096 on 115V 15 Amp Branch 15A 40 on 115V 20 Amp Branch with 20 Amp Plug OUTPUT Current Open Circuit Pilot Current Range Voltage 10 20 Amps 310 VDC 17 Amps REQUIRED AIR FLOW RATE REQUIRED AIR INLET PRESSURE 3 5 cu ft min 72 5 to 150 PSI 100L min 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 AC Input Maximum Voltage Time Delay Type SJT or Hard Usage Circuit Breaker Input Cord or Fuse Size 3 Conductor 14 AWG Weight Including Torch Cable 21 Ibs 9 5 kg 5 20 plug must comply with the standard for attachment plugs and receptacles 01498 PLASMA 20 LINCOLN 5 iim INSTALLATION A 2 Read entire Installation Section before installing
3. QUALIFIED INDIVIDUALS ELECTRIC SHOCK can kill 1 a The electrode and work or ground circuits are electrically hot when the power source is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands 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 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 shock 1 i Operate the pilot arc with caution The pilot arc is capable of burning the operator others or even pierc
4. 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 vi TABLE OF CONTENTS Page HEIDI Y Y Section Ne elle ee le EE A 1 Safety Sarica ee ec RR lp gabe tae as aere t ce ge ae ute A 2 Select Prop r Locat E A 2 ejl spec x A 2 THING ates A 2 High Frequency Interference Protection ss A 2 Input Electrical Connections A 2 Compressed Air or Gas Input A 3 Connections to Ground Cable invente ritiro heresi ipee ene EE A 3 EE REPASSER Section Safety PRECAUTIONS UCET B 1 C B 1 User Responsibility seen B 2 Design Features and Advantages ss B 2 Cutting Capability EE B 2 Reie EE lan B 2 Limitations m B 2 Controls and E el EE B 2 E TC B 3 Check lee TEE B 3 Cutting with Hand Torch ss B 3 B 4 Pilot Arc DISCUSSION euro pero A tan aee etre tec nie eee eee B 5 Torch Consumable Parts Selection
5. not part of the workpiece such as return cable of the cutting current may endanger the safety system and give poor cutting results Do not make a ground connection on the piece which is to be cut off TORCH CONNECTION Before starting the cutting operations verify that the parts are properly assembled by inspecting the head of the torch as shown in the Operations Section Torch Consumable Parts Read and understand this entire section before oper ating the machine PLASMA 20 LINCOLN 5 E OPERATION E 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 B can be dangerous Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone g WELDING CUTTING and gt GOUGING SPARKS 3 can cause fire or explosion Keep flammable material away Do not weld cut or gouge on contain ers that have held combustibles ARC RAYS B can burn Wear eye ear and body protection CF PLASMA ARC can injure Keep your body away from nozzle and plasma arc Operate the pilot arc with caution The pilot arc is capable of burning the operator others or even piercing safety clothing Observe additional Safety Guidelines detailed in the beginning of this manual DESCRI
6. CH CONSUMABLES The torch consumables consist of an Electrode Gas Distributor Ring Nozzle and Shield Cup The con sumable parts must be placed in the correct order and secured properly for the unit to operate LIMITATIONS For indoor use only Do not exceed output current and duty cycle rating of machine Do not use the PLASMA 20 for pipe thawing Do not power with generators or engine drives CONTROLS AND SETTINGS 1 ON OFF Switch In the ON position the machine is ready for normal operation All system control circuits are activated OFF position deactivates control circuits 2 Output Current Knob Adjusts the cutting current supplied by the machine according to the thick ness of material speed 3 Green LED Turns ON when input voltage is applied within normal range blinks slowly when input voltage goes above 130Vac or below 95Vac 4 Red LED Turns ON when torch is triggered Blinks quickly during 3 second safety pre flow prior to pilot arc ignition Blinks slowly if cutting arc is not initiated after 3 second pilot arc ignition 5 Yellow LED Turns ON when the thermal protec tion is activated Blinks slowly when the under pressure protection is working the pressure is under 55 PSI 3 8 Bar 6 Air Regulator Adjusts the input air pressure pull upward to unlock press down to lock nomi nal air pressure setting is 65 PSI 4 5 Bar Note Regulator should never be
7. Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your equipment identification information below for future reference This information can be found on your machine nameplate Product Model Number Code Number or Date Code Serial Number Date Purchased Where Purchased Whenever you request replacement parts or information on this equipment always supply the information you have recorded above The code number is especially important when identifying the correct replacement parts On Line Product Registration Register your machine with Lincoln Electric either via fax or over the Internet For faxing Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it For On Line Registration Go to our 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
8. IM10006 PLASMA 2U e For use with machines having Code Number 11578 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 LINCOLN Copyright 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 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 purchase a copy of Safety in Welding amp Cutting 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
9. MA 20 LINCOLN 8 WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG BIR Chinese Korean Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa 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 K rper 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 e terra 7 v 5nfdcmWn amp toc t OMIT ATWSHRIELT FSU e RLERECR JTH 2488 Se sn e xj HUE m s pad Aa Gill pl all gaali Y dr i aay ay A A el SCT aal DS dus Ye 2 9 Keep flammable materials away e Mantenga el material combustible fuera del rea de trabajo e Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflamaveis bem guarda dos
10. OFF no air flow when torch switch pressed GREEN LED ON YELLOW Over temperature under pressure LED OFF Air flows Pilot arc does not start Torch has pilot arc but does not cut TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION 1 2 Plug unit into 115V outlet Reset Breaker Make sure the unit has not been operated beyond duty cycle limits Air Flow obstructed Air not connected or pressure too low Check source for at least 72 5 PSI 5 Bar during purge or pre flow adjust air pressure to 65 PSI 4 5 Bar Air filter or air line blocked torch blocked Replace filter cartridge Check that air line and torch leads are free of twists and kinks Shield cup not properly installed on torch Check that shield cup is fully seated against torch Faulty Torch Switch or Parts Assembly in torch holder Refer to Operations Section Torch Consumable Parts Faulty Main PC Board Repair Replace Power Supply Faulty torch parts Inspect torch parts and replace if necessary Faulty main PC Board Repair replace Work lead not connected Make sure work lead is connected securely to bare metal AC input power too low Use shortest distance to breaker panel possible Faulty Main PC Board Repair Replace If all recommended possible areas of misadjustment have been checked and
11. PTION The PLASMA 20 is a constant current continuous control plasma cutter power source The PLASMA 20 comes standard with an air regulator and pressure gauge The unit is powered from a 115Vac 20 amp input circuit with a 4096 duty cycle rating on a 10 minute basis with 20 amp output The unit includes a hand held torch with consumables and a work cable with clamp The PLASMA 20 utilizes a 3 second delay after press ing the trigger before arc initiation to ensure that the operator is ready The unit will not function if consum ables are not installed correctly or missing protecting the user The unit uses pneumatic action for arc initi ation and does not use high frequency Plasma is a gas that is heated to an extremely high temperature and ionized so that is becomes a conduc tor of electricity This cutting procedure utilizes the plasma to transfer the electric arc to the metal workpiece The arc melts a small amount of the work piece and the compressed air blows away the molten metal there by producing the cutting action The torch uses compressed air from a single source for both the plasma cooling and protective gas The start of the cycle is determined by an arc called the pilot arc which is struck between the moveable electrode negative polarity and the torch nozzle positive polarity due to a short circuit between these two elements When the torch is brought near the workpiece to be cut and the trigger is p
12. R CUTTING Keep moving while cutting Cut at a steady speed without pausing Maintain the cutting speed so that the arc lag is 10 to 20 behind the travel direction 5 15 Leading Angle gt Direction of Travel Y 10 Jo Arc Lag Use a 5 15 leading angle in the direction of the cut Finish the cut to be made and release the trigger NOTE For better torch control it is acceptable to let the nozzle drag along the work piece surface This will shorten nozzle life Also it is acceptable to place a non conductive torch guide on the work piece in order to achieve a cleaner cut When the trigger is released the arc will stop The gas will continue to flow for 20 seconds of postflow If the trigger is activated within this time period the pilot arc will restart after the 3 second delay 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 Parts in place 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 electro
13. anized steel 3 b The operation of plasma cutting or gouging fume control equipment is affected by various factors including proper use and positioning of the equipment maintenance of the equipment and the specific procedure and application involved Worker exposure level should be checked upon installation and periodically thereafter to be certain it is with in applicable OSHA PEL and ACGIH TLV limits 3 c Do not use plasma cutting or gouging equipment in locations near chlorinated hydrocarbon vapors coming from degreas ing 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 follow your employer s safety practices 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 Avoid cutting or gouging near hydraulic lines Have a fire extinguisher readily availabl
14. ated FIGURE B 1 KNOB CHECKING AIR QUALITY To check air quality deactivate the torch post flow and place a welding filter lens in front of the torch Any oil or moisture in the air will be visible on the lens DO NOT initiate pilot arc while checking air quality 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 COMPRESSED AIR The PLASMA 20 requires compressed air to be attached to the unit The input air pressure mini mum must be 72 5 PSI 5 Bar and must not exceed 150 PSI 10 3 Bar An air regulator is included with the unit with optimum pressure setting set to 65 PSI 4 5 Bar The unit is also equipped with an air filter which cap tures water and oil vapor The vapor collected can be drained out of the bottom of the unit by turning the drain button The unit will not operate if the input air pressure is below 55 PSI 3 8 Bar Three Position Drain knob See Figure B 1 1 Open 2 Open when no air pressure closed when air pres sure 3 Closed CUTTING WITH A HAND TORCH 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
15. ave an qualified person service this equipment Disconnect input power by removing plug from receptacle before assem bling or disassembling torch parts or torch and lead assemblies Do not touch electrically hot parts ROUTINE MAINTENANCE 0 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 3 4 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 airstream wear appropriate eye protection Only use dry com pressed air for cleaning Do not point the jet of air at the electronic circuits 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 t
16. 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 PLASMA 20 LINCOLN OPERATION 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 3 seconds and the pilot arc will start 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 unit 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 noz zle Slowly rotate the torch to vertical position as the arc becomes deeper NOTE Graphics shown are for understanding torch angles for best results the distances from the work piece are exaggerated In actual operation the noz zle should be held just above the work piece surface TORCH AT 30 ANGLE TO PIERCE ROTATE TO 90 ANGLE TO CUT FO
17. de on the inside bottom of the nozzle to remove any oxide layer that may have built up Refer to the Routine Maintenance Section Check the condition of the electrode If the end has a crater like appearance replace it along with the nozzle The maximum wear depth of the electrode is approximately 062 A green and erratic arc will indicate definite electrode failure and the electrode should be replaced immediately Replace the nozzle when the orifice exit is eroded away or oval shaped A WARNING ELECTRIC SHOCK CAN KILL Disconnect input power by removing the plug from the receptacle before assembling or disassembling torch parts or torch and lead assemblies f the machine does not reset or continues to trip consult the Troubleshooting Section Use the proper cutting procedures referred to in Procedure Recommendations PLASMA 20 LINCOLN ES OPERATION B 5 PILOT ARC DISCUSSION The PLASMA 20 has a smooth continuous pilot arc The pilot arc is only a means of transferring the arc to the work piece for cutting Repeated pilot arc starts in rapid succes sion is not recommended as these starts will generally reduce consumable life Occasionally the pilot arc may sputter or start intermittently This is aggravated when the consumables are worn or the air pressure is too high Always keep in mind that the pilot arc is designed to transfer the arc to the workpiece and not for numerous starts without cutti
18. e 4 b Where compressed gases are to be used at the job site spe 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 Aug 06 A c SAFETY When not cutting or gouging make certain no part of the elec trode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not cut or gouge tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or gouging They may explode Do nor fuel engine driven equipment near area where plasma cutting or gouging 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 s
19. eled 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 EN from the receptacle switch before tightening cleaning or replacing consumables Turn off machine and disconnect input power by removing the plug 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 PLASMA 20 LINCOLN 8 GREEN LED OFF Fan not operat ing No Input Power GREEN LED ON YELLOW Overtemperature under pressure LED ON Unit is overheated GREEN LED ON YELLOW Over temperature under pressure LED blinks No air flow in purge or pre flow GREEN LED ON YELLOW Over temperature under pressure LED
20. erat ing machines are operating By taking the following steps high frequency interference into the PLASMA 20 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 PLAS MA 20 or possibly even damage to the control system or power supply components INPUT ELECTRICAL CONNECTIONS The PLASMA 20 must be connected to a Line Neutral system with protective grounding wire Check that the relevant electrical outlet is actually connected to the distribution system grounding The PLASMA 20 is rated for 115VAC input Use on 15 amp branch circuits will limit cutting output When the output is set at 16 amps or greater the input fuse or circuit breaker may blow in roughly 30 seconds or less depending on fuse or circuit breaker type To achieve 16 20 amp output with 115VAC input replace the 15 amp plug on the input cord with a 20 amp plug and connect the unit to a 20 amp branch circuit with
21. fin 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 LINCOLN 8 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 Mar 93 V for selecting a QUALITY product by Lincoln Electric We want you You to take pride in operating this Lincoln Electric Company product ses as much pride as we have in bringing this product to you CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment consumables and cutting equip ment Our challenge is to meet the needs of our customers and to exceed their expectations On occasion purc
22. hasers may ask Lincoln Electric for advice or information about their use of our products We respond to our customers based on the best information in our posses sion at that time Lincoln Electric is not in a position to warrant or guarantee such advice and assumes no liability with respect to such infor mation or advice We expressly disclaim any warranty of any kind including any warranty of fitness for any customer s particular purpose with respect to such information or advice As a matter of practical consideration we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given nor does the provision of information or advice create expand or alter any warranty with respect to the sale of our products Lincoln Electric is a responsive manufacturer but the selection and use of specific products sold by Lincoln Electric is solely within the control of and remains the sole responsibility of the customer Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements Subject to Change This information is accurate to the best of our knowledge at the time of printing Please refer to www lincolnelectric com for any updated information Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently
23. he cable periodically and relieve any so as not to restrict the flow of air to the torch 5 Inspect Torch Body and Handle keep thoroughly clean WITHOUT THE USE OF SOLVENTS In case of damage replace components for SAFETY CONDITIONS If repairs cannot be made on site contact a local field service shop PERIODIC MAINTENANCE A WARNING EN ELECTRIC SHOCK CAN KILL e Turn off machineand disconnect input power by removing the plug from the receptacle switch before tightening cleaning or replacing consumables Change consumables as required Torch Periodically according to use or if experiencing cutting faults inspect consumable parts associat ed with the plasma arc Shield Cup Unscrew manually from the head of the torch Clean thoroughly and replace if damaged burns distortions or cracks Nozzle Check wear of plasma arc thru hole and inner amp outer surfaces If thru hole is widened compared to it s original diameter replace nozzle If sur faces are particularly oxidized clean them with extra fine sand paper Air Distribution Ring Verify there are no burns or cracks and that air flow holes are not obstructed If damaged replace immediately Electrode Replace electrode when crater on emitting sur face is about 08 2mm WARNING Before making any adjustments to the torch let it cool the entire post flow time Except for particular cases it is advised to replace electrode and noz
24. he quality of the compressed air available it is suggested that an air dryer be installed before the input filter Using flexible airline connect the compressed air to the rear of the machine Do not exceed maximum entry pressure of 150 PSI 10 3 Bar The pressure must be adjusted to 72 5 PSI 5 Bar minimum To use the air fitting supplied with the machine apply teflon tape to the fitting threads and install the fitting in the port at the rear of the machine 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 PLASMA 20 regulator should never exceed 150 psi 10 3 Bar Install a hose between the nitrogen gas cylin der regulator and the PLASMA 20 gas inlet A WARNING CYLINDER could explode if damaged Keep cylinder upright and chained to a fixed support e Never lift machine with cylinder attached e Never allow the cutting torch to touch the cylin der Keep cylinder away from live electrical parts e Maximum inlet pressure 150 PSI 10 3 Bar CONNECTION TO GROUND CABLE Connect the work cable clamp to the piece to be cut or to the metallic workbench Take the following pre cautions Verify that there is a good electrical contact particular ly if insulated or oxidated coated sheets are cut Make ground connections as close as possible to the cutting area The use of the metallic structures which are
25. hields when in a cutting or gouging area Connect the work cable to the work as close to the cutting or 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 Read and follow NFPA 51B Standard for Prevention During Welding Cutting and Other Hot Work available from NFPA 1 Batterymarch Park PO box 9101 Quincy Ma 022690 9101 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 5 d 5 e 54 5 g 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 val
26. ible 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 cables 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 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 du corps PR CAUTIONS DE S RET POUR Un coup d arc peut tre plus s v re qu un coup de soliel LES MACHINES SOUDER SE TRANSFORMATEUR ET A a Utiliser un bon masque avec un verre filtrant appropri REDRESSEUR 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 1 b Porter des v tements convenables a
27. ing safety clothing 1 j Also see Items and 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 gt 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 2 b Use suitable clothing including gloves made from durable flame resistant material to protect your skin and that of your helpers from the arc rays 2 c Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal LINCOLN FUMES AND GASES can be dangerous 3 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 zone When plasma 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 plasma cutting or gouging on galv
28. k the threads before proceeding FIGURE B 2 SHEILD CUP nme NOZZLE GAS DIFFUSER RING tery dE TORCH HEAD ASSEMBLY OPERATING FAULTS During cutting operations performance faults may arise such as Insufficient penetration too high cutting speed torch is tilted piece is too thick cutting current is too low torch parts are worn out non genuine Manufacturer s parts Interruption of the cutting arc cutting speed too slow excessive distance between torch and work piece Input Voltage too low reduce output current torch parts are worn out non genuine Manufacturer s parts poor work cable connection disconnected Excessive slag dross too low cutting speed bottom dross too high cutting speed top dross excessive distance between torch and work piece cutting current too low torch parts are worn out non genuine Manufacturer s parts Tilted cutting not perpendicular torch position not correct asymmetric wear of nozzle hole and or incorrect assembly of the torch parts Excessive wear of nozzle and electrodes air pressure too low exceeding system capability material too thick contaminated air humidity oil excessive pilot arc ignitions in the air improperly assembled torch torch nozzle contacting workpiece damaged or loose torch head components non genuine Manufacturer s parts PLASMA 20 LINCOLN B MAINTENANCE D 1 A WARNING ELECTRIC SHOCK can kill H
29. ng 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 A WARNING e ELECTRIC SHOCK CAN KILL Disconnect input power by removing the plug from the receptacle before assembling or disassembling torch parts or torch and lead assemblies Be sure the operator is equipped with proper gloves clothing eye and ear protection Make sure no part of the operator s body comes in contact with the work piece while the torch is activated CAUTION Sparks from the cutting process can cause dam age to coated painted and other surfaces such as glass plastic and metal NOTE Handle torch cable with care and protect it from damage TORCH CONSUMABLE PARTS SELECTION To change the torch consumable parts use the follow ing procedure NOTE The nozzle gas distributor and electrode are held in place by the shield cup Position the torch with the shield cup facing upward to prevent these parts from falling out when the cup is removed 1 Unscrew and remove the shield cup from the Torch Head Assembly Figure B 2 Consumable Parts 2 Remove the nozzle gas distributor and electrode 3 Install the electrode gas distributor and nozzle 4 Hand tighten the shield cup until it is seated on the torch head If resistance is felt when installing the cup chec
30. ressed the pilot arc is trans ferred between the electrode and the workpiece thus striking a plasma arc also called the cutting arc The duration of the pilot arc is set in the factory at 3 seconds if the transfer has not been made within this time the cycle is automatically stopped except for the cooling air which is kept on PLASMA 20 LINCOLN 5 2 OPERATION B 2 USER RESPONSIBILITY Variation such as plate chemistry plate surface condi tion oil scale plate thickness preheat quench gas type gas flow rate and equipment may produce results different than those expected Some adjust ments to procedures may be necessary to compen sate for unique individual conditions Test all proce dures duplicating actual field conditions DESIGN FEATURES AND ADVANTAGES Light weight Continuous output control Indicator LEDs Cooling fan Rapid arc restrike for cutting across gaps 3 second arc delay for safety Adjustable air pressure regulator with locking feature Part in place verification for safety and proper operation Thermostatic protection with thermal indication Air inlet filter with water purge button to protect air path and torch Lighted ON OFF switch High input voltage protection CUTTING CAPABILITY The PLASMA 20 is rated for 20A 40 duty cycle The unit is designed to cut up to 3 8 inch mild steel but has the capability to cut other metals such as stainless and aluminum travel speed will vary TOR
31. set above 87 PSI 6 Bar 7 Compressed Air Connection 8 Input Cord 9 Work cable with clamp 10 Torch PLASMA 20 LINCOLN nil OPERATION B 3 CUTTING OPERATIONS BEFORE CUTTING WARNING ELECTRIC SHOCK KILL Disconnect input power by removing the plug from the receptacle before assembling or disassembling torch parts or torch and lead assemblies Check and follow instructions listed in the Safety and Installation section of this manual TORCH PARTS Check the torch for proper assembly Install proper torch parts for the desired application refer to the Torch Consumable Parts Selection Section NOTE The power supply will not operate unless the torch shield cup is fully seated against the PIP Parts in Place pins in the torch head INPUT POWER Check the power source for proper input voltage Make sure the power source meets circuit protection and wiring requirements Plug in power cord to supply input power to the unit GROUND CABLE Check for a solid ground cable connection to the workpiece AUTOMATIC PURGE SYSTEM Place the ON OFF switch to the ON position If the line voltage is OK the green LED will turn on Activate the torch trigger to initiate air purge There will be a 3 second delay to remove any condensation that may have accumulated in the torch and air lines while the system was shut down When the air purge Air safety time is complete pilot arc will be initi
32. sez 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 eE1i LDS HEMT ETELT 13 1 8 e OER E 5 2475 257130295 297158 Ash 712724714 SSE Lan ul jan Sal las As j Aog I e A ui A Mail 9 e Turn power off before servicing e 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 e Desligue a corrente antes de fazer servico e toque as partes el tricas nuas X2TTLA Y AIEUSD PSR e AHS xps Sien Ae d i A hg 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 mo
33. 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 Ne 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 contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie soudage Utiliser des lunettes avec crans lateraux dans les zones ou l on pique le laitier 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 poss
34. super lag fuses or equivalent breaker To install 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 5 20P plug must comply with the standard for attach ment plugs and receptacles UL498 This product is acceptable for use only when an attachment plug as specified is properly attached to the supply cord 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 PLASMA 20 LINCOLN 5 INSTALLATION A 3 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 COMPRESSED AIR OR GAS INPUT CONNECTION A source of clean dry air or nitrogen must be supplied to the PLASMA 20 Oil in the air is a severe problem and must be avoided The supply pressure must be between 72 5 and 150 psi 5 and 10 3 bar The flow rate is approximately 3 5 cu ft min 100L min Failure to observe these precautions could result in excessive operating temperatures or damage to the torch A WARNING Air with considerable quantity of humidity or oil may cause an excessive wear of the parts or even damage the torch If there are any doubts about t
35. sure 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 8 d 2 8 d 3 LINCOLN 5 Route the torch and work cables together Secure them with tape when possible Never coil the torch cable around your body 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 Jan 07 NOTES LINCOLN B SAFETY PR CAUTIONS DE S RET 5 Toujours porter des lunettes de s curit dans la zone de 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
36. the PLASMA 20 SAFETY PRECAUTIONS A WARNING ELECTRIC SHOCK CAN KILL Only qualified personnel should perform this installation Only personnel that have read and understood the PLASMA 20 Operating Manual should install and operate this equipment Machine must be plugged into a receptacle which is grounded per any national local or other applicable electrical codes The PLASMA 20 power switch is to be in the OFF O position when installing work cable and gun and when connecting power cord to input power SELECT PROPER LOCATION Place the PLASMA 20 where clean cool air can freely circulate in and out the front rear and side louvers Dirt dust smoke gas or any foreign material that can be drawn into the machine should be kept at a mini mum Insure open space of at least 15 ft around the machine Failure to observe these precautions can result in excessive operating temperatures and nui sance shutdown of the machine STACKING The PLASMA 20 cannot be stacked TILTING The PLASMA 20 must be placed on a stable level surface so it will not topple over HIGH FREQUENCY INTERFERENCE PROTECTION The PLASMA 20 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 gen
37. the problem persists Contact your local Authorized Field Service Facility CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed PLASMA 20 LINCOLN 8 F 1 DIAGRAMS Jequunu epoo jueuudinbe SAID e eui 0 e qiGeji eu JI pejsed si epoo sejnomed e oul enueui siy Aq seuluoeui e1eno2oe eq jou 2 VIONVO3dNI 7 3 0H2 3401V10934 01114 1 93 3 IV 341114 30 0384 3113 VIONOL VHOMOINV NOLNOS NOLING Hsnd 19 01915055344 0191505394 1915055344 ur vuosxonuaLIm 1915055344 1313 10373 3NNVAONLT3 77190517379 INWA GIONTIOS LA 440 430 NO 440 NO 440 NO 440 NO 15 656 quvoa AV Idi sjeued eunsojoue JO euo uo eui 10 S 4141 310 PLASMA 20 LINCOLN amp NOTES PLAS
38. ve 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 oylin ders associated equipment and CGA publication P l Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 6 a Turn off input power using the disconnect switch at the fuse box before working on the equipment 6 b Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s rec ommendations 6 c Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations PLASMA ARC can injure 7 a Keep your body away from nozzle and plasma arc 7 b Operate the pilot arc with caution The pilot arc is capable of burning the operator others or even piercing safety clothing ELECTRIC AND MAGNETIC FIELDS may be dangerous 8 a Electric current flowing through any 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 Expo
39. ventes opere com os paineis abertos ou guardas removidas e SIPH ERAL EE ero Sel Sa ORY AIS Abe y Gis 10 al la Chany Ad gl WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO tm BIR Chinese LEIA E COMPREENDA AS INSTRUCOES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANGA DO EMPREGADOR 2 4898 CL TRHOKRSMEI HT FEU GIE AE OE BO ELE LR RER REINA MARTRAHARSHRERE ZS Se oo AIX A HS 75 HAS SsbA uHc ve kel 38 dl i al 9 l SOU Glues candy 9 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
40. zle AT THE SAME TIME Insure correct assembly order of torch parts Be careful that gas distributor ring is assembled properly Reassemble shield cup screwing it on manually hand tighten Never assemble shield cup without having included gas distributor ring and nozzle beforehand Timely and appropriate maintenance on torch parts is essential for safety and proper functionality of the cutting system PLASMA 20 LINCOLN 8 pii MAINTENANCE D 2 COMPRESSED AIR FILTER The unit is supplied with a filter for the compressed air and fitted with a manual drain for condensation Drain is located on the bottom of the filter Purge periodical ly to remove the water in the filter by opening the drain knob Do not use solvents to clean the filter use soapy water only PLASMA 20 LINCOLN 8 E TROUBLESHOOTING E HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty For your safety and to avoid Electrical Shock please observe all safety notes and precautions detailed throughout this manual This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column lab
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