Lincoln Electric MAGNUM PCT125 User's Manual
Contents
1. 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 pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de levage cables 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 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 11 Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety2. 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 xv 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 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 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 spr
3. IM543 Magnum PCT125 PCT125M Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind However your overall safety can be increased by proper installation and thoughtful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READ ING THIS MANUAL AND THE SAFETY PRECAUTIONS CON TAINED THROUGHOUT And most importantly think before you act and be careful OPERATOR S MANUAL LI NCOLN Copyright 2004 Lincoln Global Inc World s Leader in Welding and Cutting Products e Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com SAFETY PLASMA CUTTING or GOUGING can be hazardous WARNING 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 Cutting ANSI Standard 49 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 PER FORMED ONLY BY QUALIFIED INDIVIDUALS ELECTRIC SHOCK can kill 1 a The electrode and
4. e Entfernen Sie brennbarres Material e Mantenha inflam veis bem guarda dos e Hao d 6008 CORE TEX LU THEW EGA o Ei 2 VUE S BET FIST o Ha 7 5 day gs AL 4 gl aa Wear eye ear and body protection e 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 e corpo e H BRUSH RBAELTE eu Om HRSRSIREAR ex 79 Pears 5 52 dM y due de Al y usa y au o deua 9 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 PLASMA TORCH LINCOLN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piracion Ma
5. It is best to minimize the pilot arc A WARNING time in order to prolong consumable life Starting at the edge of the work piece instead of piercing the When plasma cutting it is necessary to wear material increases consumable life also proper eye head and body protection H Release the trigger when the cut is complete Air will continue to flow for 60 seconds to cool the torch A Connect the work lead to the material to be cut This is called POSTFLOW B Assemble an electrode swirl ring nozzle and shield cup on the torch C Turn the Pro Cut ON with the power switch on the front of the Pro Cut D Flip the Run Purge switch to PURGE Adjust the regulator until the pressure gage reads 55 65 psi 379 448 kPa Flip the Run Purge switch to RUN Air will continue to flow for 60 seconds because the Pro Cut will be in post flow E Adjust the output to the desired level Refer to the appropriate Lincoln Process and Procedure Guidelines for recommended output standoff noz zle and cutting technique for your application F Activate the trigger e Ifthe air was not already flowing the Pro Cut will allow the air to flow for two seconds before the pilot arc is started This is called PREFLOW e fthe trigger was activated during the first twelve seconds of postflow then a pilot arc will start instantly To start an arc after the first twelve seconds of postflow it will be necessary to perform a double trigger
6. Cut 2 Using a 5 8 open end wrench loosen and unscrew the nut securing the gas tube to the bulkhead union PLASMA TORCH LINCOLN INSTALLATION A 3 Unscrew the wing nut and remove the pilot lead of the torch cable from the pilot stud Loosen the strain relief cap using channel locks if necessary Then loosen and unscrew the strain relief from the conduit lock nut Slide the cable through the conduit lock nut and out through the hole in the case front D To assemble a torch to the Pro Cut 1 Slide the end of the cable through the hole in the case front Then slide the conduit lock nut over the end of the cable With a 5 8 wrench tighten the fitting at the end of the gas tube onto the bulkhead union Place the ring lug of the pilot leads from the cable over the pilot stud Place the wing nut on the pilot stud and tighten Connect the two molex connectors from the torch to the molex connectors in the Pro Cut Loosen the cap on the strain relief Slide the strain relief into the hole in the case front Screw the conduit lock nut on to the strain relief and tighten the strain relief with channel locks Hand tighten the strain relief cap and then tighten the cap an additional 1 2 turn with channel locks 6 For mechanized torches only See diagram below Without an interface kit Remove the top cover by loosening the sheet metal screws with a 5 16 nut driver Remove the blac
7. en cuir chemise paisse pan 4 Garder tous les couvercles et dispositifs de s ret leur place 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 les zones ou l on pique le laitier LINCOLN geri for selecting a QUALITY product by Lincoln Electric We want you Thank You 5 0 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 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 e For faxing Complete the form on the back of the warranty statement included in the literature packet accompanying this machine
8. pull consisting of activating releasing and activating the triggering within a one second period PLASMA TORCH LINCOLN B C 1 MAINTENANCE C 1 MAINTENANCE 44 WARNING ELECTRIC SHOCK CAN KILL e Only qualified personnel should per form this installation e Turn the input power OFF at the dis connect switch or fuse box before working on this equipment Do not touch electrically hot parts Do not operate with covers removed Keep the work area clean and free of combustible materials Prevent debris and objects from obstructing air flow around the Pro Cut Every few months blow the dust off the air intakes and louvers with compressed air Check the filter elements every several months to see if they are clogged weekly in very dirty environments Replace if necessary Inspect the cable periodically for any slits or puncture marks in the cable jacket Replace if necessary Check to make sure that nothing is crushing the cable and blocking the flow of air through the air tube inside Also check for kinks in the cable and relieve any so as not to restrict the flow of air to the torch Replace the electrode when the pit in the center of the electrode is deeper than 050 1 3 mm or when the copper portion is severely distorted Replace the nozzle when the orifice is no longer round or when the inside surface is covered with scale Green colored arcs indicate the electrode and or nozzle are worn and ne
9. 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 insu late hands 1 6 When the power source is operating voltages in excess of 250 volts are produced This creates the poten tial for serious electrical shock potentially even fatal 1 c Insulate yourself from work and ground using dry insulation When cutting or gouging in damp locations on metal 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 1 d 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 1 e 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 1 g Never dip the torch in water for cooling or plasma cut or gouge in or under water 1 h When working above floor level protect yourself from a fall should you get a shock 1 i Operate the pilot arc with caution The pilot arc is capable of burning the operator others or even piercing safety clothing 1 j Also see Items 4c and 6 ARC RAYS can burn
10. 3 PCT125M Plasma Machine Torch with 50 ft 15 2m cable and 24 and 32 pitch gear racks aK880 4 PCT125M Robotic Plasma Torch with 50 ft 15 2m cable K880 5 PCT125 Hand held Plasma Torch with 25 ft 7 6m cable OUTPUT RATING 125 Amps 60 Duty Cycle 100 Amps 100 Duty Cycle NET WEIGHT a K880 1 PCT125 Hand held Plasma Torch with 25 ft 7 6m cable 11 5 Ibs 5 2 kg K880 2 PCT125 Hand held Plasma Torch with 50 ft 15 2m cable 21 5 Ibs 9 8 kg a K880 3 PCT125M Plasma Machine Torch with 50 ft 15 2m cable 21 5 Ibs 9 8 kg K880 4 PCT125M Robotic Plasma Torch with 50 ft 15 2m cable 21 5 Ibs 9 8 kg K880 5 PCT125 Hand held Plasma Torch with 25 ft 7 6m cable 12 0 lbs 5 4 kg TORCH COMPONENTS KP2045 1 Shield Cup with u optional KP2046 1 standoff KP2042 1B1 055 1 4 mm orifice guide or optional KP2047 1 _ g KP2042 2B1 067 1 f mm orifice gouging attachment KP2042 3B1 075 1 9 mm orifice KP2042 4B1 118 3 0 mm orifice for gouging 519974 Contact Cutting Attachment with required 9199759 Contact Cutting Insulator KP2045 1 or 2 Shield Cup with optional KP2046 1 standoff guide or optional KP2047 1 gouging attach KP2042 1B1 055 1 4 mm orifice ment K880 5 KP2043 1B1 KP2044 1 KP2042 2B1 067 1 7 mm orifice KP2042 4B1 118 3 0 mm orifice for gouging Attachment with required S19973 or S19973 1 Contact Cutting Insulator Option Kits K881 1 Spare Parts Kit K952 1
11. LATION SHEET b Tightly wrap the insulation sheet around the fit tings and underneath the stem for the pilot con nection of the torch head Secure the insulation in place with two pieces of electrical tape 14 Assemble the leads from the cable to the torch head per the following diagram It is not important which side of the torch head the red and the white lead mount Y ux WASHER b For replacing the cable assembly slide the N Emm insulating tube barrel strain relief and boot off BLACK of the old cable Obtain a new cable and dis ae card the old cable If the boot becomes sepa WHITE rated from the strain relief insert the boot under the fingers of the strain relief before sliding the LOCK WASHER parts onto the new cable Slide the following TH PLAIN WASHER WHITE LOCK WASHER PLASMA TORCH LINCOLN amp C 4 MAINTENANCE C 4 15 Slide the insulating tube over the cable and torch head connections to the back of the torch head and align the holes in the insulating tube with the holes in the torch head HOLE IN TORCH HEAD SLIDE BARREL INSULATING TUBE 16 Slide the barrel over the insulating tube aligning the holes in the barrel with the holes in the insulat ing tube Secure the barrel and tube in place with the set screws and tighten with a 5 64 Allen wrench A SET SCREW 17 Slide the strain relief with the cable boot into the barrel Do not allow the boot to slip out from un
12. LE 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 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 TORCH LINCOLN D 2 TROUBLESHOOTING D 2 Observe all Safety Guidelines detailed throughout this manual PROBLEMS RECOMMENDED SYMPTOMS COURSE OF ACTION FUNCTION PROBLEMS The torch does not start when the a Blown fuse a Make sure all three phases are trigger is pulled present and the Pro Cut is reconnected for the proper volt age b Electrode or nozzle missing Properly assemble an electrode swirl ring nozzle and shield cup on the torch c Torch misconnected Make sure the pilot lead from the torch cable is connected to the pilot stud inside the Pro Cut Verify that the fitting at the end of the gas tube is connected to the bulkhead union inside the Pro Cut d Cable damaged Examine the cable for cuts or punctures M
13. Robotic Machine Torch Retrofit Kit required when using a machine torch with a machine code 10119 or below Torch is no longer available PLASMA TORCH LINCOLN B A 2 INSTALLATION A 2 GENERAL DESCRIPTION The Magnum PCT125 PCT125M plasma torches have been designed for use on a Pro Cut 125 All of the torches are single gas air cooled The torches are supplied factory mounted to the Pro Cut or can be bought as individual units The hand held torch is available only with a 70 head It is supplied with either a 25 ft 7 6m or 50 ft 15 2m cable Two styles of mechanized torches are available The robotic torch features an 8 203mm long 1 5 8 42 3mm diameter barrel The machine torch has a 12 305mm long 1 3 8 34 9mm diameter barrel with a 32 pitch gear rack The 32 pitch gear rack can be easily substituted with a 24 pitch gear rack which is included with the machine torch The mechanized torches are offered only with 50 ft 15 2m cables Included with all mechanized torches is a 25 ft 7 6m arc starter switch assembly for triggering the Pro Cut without the use of an interface kit CNC or Robotic interface kits are available as a field installed option for those customer desiring automated plasma cutting The kits provide remote triggering remote output control and give a signal once a cutting arc has been established All of the plasma torches use the same consumables In order to operate a torch must have
14. ake sure there is continuity from the nozzle at the torch head to the ring lug at the end of the pilot lead at the machine end of the cable Make sure there is continuity from the electrode at the torch head to the fitting at the end of the gas tube at the machine end of the cable replace any dam aged cable e Torch connections assembled Remove the handles or barrel improperly or shorted of the torch and examine all the connections Pay attention to lugs crimped on insulation bro ken leads f Pro Cut inoperative Refer to the troubleshooting guide for the Pro Cut 125 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 TORCH LINCOLN D 3 TROUBLESHOOTING D 3 Observe all Safety Guidelines detailed throughout this manual PROBLEMS RECOMMENDED SYMPTOMS COURSE OF ACTION FUNCTION PROBLEMS The Safety LED is lit The Pro Cut was quickly turned Press the SAFETY RESET but off then on again ton The shield cup is missing Make sure an electrode swirl ring nozzle and shield cup are all properly assembled on the torch The shield cup is not making Verify that the spring loaded ring contact with the pins of the torch in the back of the shield cup is head not jammed Replace as nec
15. an electrode swirl ring nozzle and shield cup There are three cut ting nozzles available to give optimum arc perfor mance at low medium and high output A gouging nozzle is also available Drag cutting can be done by placing a wire standoff guide on to the shield cup or by using a contact cutting attachment and contact cutting insulator in place of the shield cup Operation from bottled compressed air or gas cylinders is not recommended due to the large volume of gas required for plasma cutting INSTALLATION WARNING N e ELECTRIC SHOCK can kill e Only qualified personnel should per form this installation e Turn the input power OFF at the dis connect switch or fuse box before working on this equipment e Do not touch electrically hot parts e Do not operate with covers removed TOOLS REQUIRED 5 16 nut driver 5 8 open end wrench channel locks Bulkhead Union Molex Connecter Molex Connector Gas Tube Strain Relief Cap Lock Nut FIGURE A 1 Torch Connections A Turn off power to the Pro Cut at the disconnect switch or fuse box Do not proceed until the power is definitely turned off B Using a 5 16 nut driver remove the sheet metal screw which holds the access door shut on the right side of the Pro Cut Open the door C To remove a torch from the Pro Cut refer to Figure A 1 and do the following 1 Separate the two molex connectors from torch to the Pro
16. and fax the form per the instructions printed on it e 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 PLASMA TORCH LINCOLN VI TABLE OF CONTENTS Page SPECIFICATION SUMMARY ee nee A 1 GENERAL DESCRIPTION essen ee A 2 INSTALLATION ent ee ee secs A 2 OPERATIONS ee ee een B 1 MAINTENANCE ee ee C 1 TORCH HEAD AND CABLE REPEAGEMENT ee C 2 TROUBLE ee ee ee ad ee D 1 x Rlledultl P210 C G PLASMA TORCH LINCOLN vi A 1 INSTALLATION A 1 SPECIFICATIONS SUMMARY TYPE K880 1 PCT125 Hand held Plasma Torch with 25 ft 7 6m cable a K880 2 PCT125 Hand held Plasma Torch with 50 ft 15 2m cable a K880
17. aying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating products 3 c Gases used for plasma cutting and gouging can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe 3 d Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employ er s Safety practices CUTTING SPARKS can cause fire or explosion 4 a Remove fire hazards from the plasma cutting or gouging area If this is not possible cover them to prevent the cutting or gouging sparks from starting a fire Remember that welding sparks and hot materials from plasma cutting or gouging can easily go through small cracks and openings to adjacent areas Avoid cutting or gouging near hydraulic lines Have a fire extinguisher readily available 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 equipment being used 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 o
18. cables or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they 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 5 b Always keep cylinders in an upright position securely chained 5 c Cylinders should be located e 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 burning the operator others or even piercing safety clothing ELECTRIC AND MAGNETIC FIELDS may be dangerous 3 to an undercarriage or fixed support E 8 a Electric current flowing through any conduc S SN tor causes localized Electric and Magnetic Fields EMF Cutting or gouging current creates EMF fields around torch cables and cutting machines 8 b EMF fields may interfere with some pace makers so operators having a pacemaker should consult their physician before cutting or gouging Never allow any part of the electrode torch or any other elec 8 c Exposure to EMF fields during cutting or gouging may have trically hot parts to touch a cylinder Keep your head and face away from the cylinder valv
19. der neath the fingers of the strain relief Align the holes in the strain relief with the holes in the barrel Secure the barrel to the strain relief with the sock et head cap screws and tighten with a 9 64 Allen wrench ZEIT IT dll AMAS 18 Tighten the strain relief cap hand tight and then tighten an additional half turn with channel locks 19 Place the hose clamp around the boot Assemble the hose clamp such that it is snug around the boot HOSE CLAMP 7 20 Restore power to the machine PLASMA TORCH LINCOLN amp D 1 TROUBLESHOOTING D 1 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 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 POSSIB
20. e outlet when opening the cylinder valve 5 f Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use 5 g Read and follow the instructions on compressed gas cylin ders associated equipment 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 LINCOLN other health effects which are now not known 8d All operators should use the following procedures in order to minimize exposure to EMF fields from the cutting or gouging circuit 8 d 1 Route the torch and work cables together Secure them with tape when possible 8 d 2 Never coil the torch cable around your body 8 d 3 Do not place your body between the torch and work cables If the torch cable is on your right side the work cable should also be on your right side 8 d 4 Connect the work cable to the workpiece as close as possible to the area being cut or gouged 8 d 5 D
21. ed to be replaced PLASMA TORCH LINCOLN B C 2 MAINTENANCE C 2 REPLACEMENT INSTRUCTIONS FOR PCT125M CABLE AND TORCH HEAD ASSEMBLY A WARNING e ELECTRIC SHOCK can kill e Turn the input power off to the Pro Cut using the disconnect switch at the fuse box before attempting to replace either the torch head or the cable assembly e Only qualified personnel should install service or use this equipment e Read instructions thoroughly before beginning Tools Required two 5 8 open end wrenches 7 16 open end wrench channel locks roll of electrical tape 5 64 Allen wrench 9 64 Allen wrench small flat bladed screwdriver NOTE The pictures illustrate the robotic torch The procedure for replacing components on the machine torch is similar 1 Be sure power is OFF to the machine by using the disconnect switch at the fuse box Do not proceed until power to the machine is disconnected 2 Use a small flat bladed screwdriver to relieve ten sion on the hose clamp around the boot Remove the hose clamp from the torch 3 Loosen the strain relief cap using channel locks if necessary STRAIN RELIEF CAP 4 Remove the socket head screws holding the strain relief to the barrel with a 9 64 Allen wrench SOCKET HEAD SCREW 4 4 u N N d 5 Slide the boot strain relief cap and strain relief as a complete unit about one foot along the cable 6 Use a 5 64 Allen wrench to rem
22. es sary Torch misconnected Make sure the pilot lead from the torch cable is connected to the pilot stud inside the Pro Cut Verify that the fitting at the end of the gas tube is connected to the bulkhead union inside the Pro Cut Cable damaged Examine the cable for cuts or punctures Make sure there is continuity from the nozzle at the torch head to the ring lug at the end of the pilot lead at the machine end of the cable Make sure there is continuity from the electrode at the torch head to the fitting at the end of the gas tube at the machine end the cable Replace any dam aged cable f Standoff too high Maintain a standoff of 15 to 25 during cutting Too high of a standoff may trip the safety circuit g Pro Cut inoperative Refer to the troubleshooting guide for the Pro Cut 125 44 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 TORCH LINCOLN TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS RECOMMENDED SYMPTOMS COURSE OF ACTION Only a brief spurt of a Pilot Arc appears Electrode Stuck in Torch head FUNCTION PROBLEMS Make sure the air pressure is set correctly Consumables may be improper ly assembled There may be
23. in welding and cutting CSA Standard W 117 2 1974 PR CAUTIONS DE S RET POUR contre les chutes dans le cas ou on recoit un choc Ne jamais LES MACHINES A SOUDER A enrouler le c ble lectrode autour de n importe quelle partie du TRANSFORMATEU R ET A 2 Dans le cas de travail au dessus du niveau du sol se prot ger corps REDRESSEUR Un coup d arc peut tre plus s v re qu un coup de soliel donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du rayon nement 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 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 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 de l huile tels que les gants
24. ispositifs de protection enlev s e Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes e N o opere com os paineis abertos ou guardas removidas O0ONAIPAN ERMVALIZE TRBHRPFELEVCE FL e SESS E ES NS Ko edo Y OM AIS GEBEN cils 1 la Jedd y e die Coal Ail all Gago Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO Se 58 Chinese LEIA E COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PR TICAS DE SEGURANCA DO EMPREGADOR ES HERRERO 2 HDBETRE TEC RA EFBRLTF EW CLTRHORSRMELTE STR EU E EE ARE UE TS AROS ESE LS 11350 Saz BELEH AIXIAIME SSID FAS Aix ORAE E S El Jarl cala Al gil caladas y Lila Sub al gg all El giall clala y ay il PLASMA TORCH LINCOLN LINCOLN e World s Leader in Welding and Cutting Products e Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com
25. k hole plug from the left side of the front panel of the Pro Cut Disconnect the Pro Cut s wiring harness at J5 in the lower right corner of the control board mounted on the center panel Insert the plug and lead assembly molex jumper that came with the mechanized torch into J5 on the control board Plug the Pro Cut s wiring har ness plug into the jumper Mount the strain relief to the front panel of the Pro Cut Insert the arc starter cable terminals first into the Pro Cut and connect the cable to the plug and lead assembly Tighten the strain relief onto the arc starter cable Replace the top cover and insert the sheet metal screws E Close the access door and screw in the sheet metal screw with a 5 16 nut driver F Restore power to the Pro Cut CONTROL P C A BOARD E inm BULKHEAD BOX PLUG amp CONNECTOR LEAD ASSEMBLY MAIN HARNESS o ARC nam PLASMA TORCH LINCOLN B 1 OPERATION B 1 OPERATION G Bring the pilot arc close to the material to be cut Once the torch is about 1 8 to 1 4 3 mm to 6 mm Refer to your Pro Cut operator s manual for complete away from the work piece the arc will automatically operating information transfer to the work and the Pro Cut will regulate output to the setting on the dial or to the signal from an interface kit
26. ntenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases e Gardez la t te l cart des fum es e Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail e Vermeiden Sie das Einatmen von Schweibrauch e Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes e Mantenha seu rosto da fumaca e Use ventilac o e exhaust o para remover fumo da zona respirat ria E11 LISRZETLIELT Feb TRS o TAPD R AEE S o OR E 6 A X E ak ASER TS e e 42274 372 e S AIACETE amp 87 amp 3171571 AS 22174214 Sele MSHS Ql OF lis ll y sui e CAS ll bia ja Aj geil Jarl Li Qu A gl as 2 Wels sg 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 e Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten e N o opere com as tampas removidas e Desligue a corrente antes de fazer servico e N o toque as partes el tricas nuas 0 X DP PSR STEEL Fe gt 0 ie TRS Us e 6 81 0 18 A pill Gab ily ail 9 Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas e N op rez pas avec les panneaux ouverts ou avec les d
27. o not work next to cutting power source Apr 93 NOTES LINCOLN SAFETY PRECAUTIONS DE SURETE 6 Eloigner les mat riaux inflammables ou les recouvrir afin 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 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 met allique 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 defonc tionnement 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
28. oil in the air The Pro Cut may be in expand ed metal mode The swirl ring may have holes out of spec The Pro Cut is not working prop erly The duty cycle may have been exceeded Make sure the Pro Cut has the larger solenoids this applies to codes 10097 and lower only Make sure the air pressure is set properly PLASMA TORCH LINCOLN amp a Put the Pro Cut in Purge and adjust the air pressure to 55 65 psi while the air is flowing Make sure an electrode swirl ring nozzle and shield cup are assembled in the torch Check the filters in the regula tors for oil Replace if neces sary and eliminate the source of oil This is a normal condition which occurs after several long pilot arcs have been pulled in a row After a while the Pro Cut will return to the standard pilot arc if no pilot arcs are pulled for sev eral seconds Some swirl rings were shipped with the swirl hole diameter too large If possible use plug gages to make sure the swirl hole diameter is not larger than 028 Refer to the troubleshooting guide for the Pro Cut 125 Operate the Pro Cut within the duty cycle limits 125 Amps at 60 100 Amps at 100 Install a S21237 solenoid kit Put the Pro Cut in Purge and adjust the air pressure to 55 65 psi while the air is flowing 44 CAUTION If for any reason you do not understand the test procedures or are unable to perform
29. ove the set screws securing the barrel to the torch head 7 Slide the barrel and insulating tube along the cable to reveal the cable to torch head connections CABLE TO TORCH HEAD CONNECTIONS SLIDE 8 Using a flat bladed screwdriver loosen and remove the screws securing the leads from the cable to the torch head PLASMA TORCH LINCOLN C 3 MAINTENANCE C 3 En WASHER Y PLAIN WASHER BLACK Waser WASHER en PLAIN WASHER WHITE amp LOCK WASHER 9 Untape and remove the insulation INSULATION 10 Separate the torch head from the cable using two 5 8 open end wrenches PLACE WRENCHES HERE 11 Replace the torch head or cable assembly as fol lows a To replace the torch head remove the fitting from the old torch head by using a 5 8 open end wrench and a 7 16 open end wrench Discard the old torch head and obtain a new torch head Place the fitting on the new torch head and tighten with the wrenches PLACE WRENCHES HERE parts on to the new cable in this order Boot and strain relief barrel insulating tube 12 Assembly the torch head to the cable and tighten the fittings using two 5 8 open end wrenches PLACE WRENCHES HERE 13 Attach the insulation sheet as follows a Use a piece of electrical tape to attach the insu lation to the fitting Center the insulation so that all of the fittings and the hose clamp will be completely covered TAPE INSU
30. r containers until the prop 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 Vent hollow castings or containers before heating cutting or gouging They may explode 4 f Do nor fuel engine driven equipment near area where plasma cutting or gouging LINCOLN ii SAFETY 4 g Sparks and spatter are thrown from the plasma arc Wear safe ty 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 goug ing out of position or in confined places Always wear safety glasses with side shields when in a cutting or gouging area 4 h Connect the work cable to the work as close to the cutting or LE PLASMA ARC can injure 7 a Keep your body away from nozzle and plasma arc gouging area as practical Work cables connected to the build 7 b Operate the pilot arc with caution The pilot arc is capable of ing framework or other locations away from the cutting or goug ing area increase the possibility of the current passing through lifting chains crane
31. the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed NOTES PLASMA TORCH LINCOLN amp NOTES PLASMA TORCH LINCOLN NOTES PLASMA TORCH LINCOLN WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO Japanese eS 58 Korean Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground e No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y de la tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pieces sous tension e 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 N o toque partes el tricas e elec trodos com a pele ou roupa molha da e Isole se da peca e terra BE POE AA F PMN Fe Ft CMNEWUTE XP 5 SR NTWSRILT FAY e X BA SCR YU DEBATE AR OR E CERATI AA Jui ll gu Gil ja Quali Y pal ala ag el ds ell Ald pla DIS dua ule Vile pue Keep flammable materials away Mantenga el material combustible fuera del area de trabajo e Gardez l cart de tout mat riel inflammable
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