Lincoln Electric 980 Welder User Manual
Contents
1. Qty Titles Machine Codes Manual Unit Price Total Price Square Wave Tig 255 Codes 10022 10134 SVM100 A 45 00 V300l Codes 9826 10133 SVM101 A 45 00 SP100 Codes 9284 10050 SVM102 A 45 00 Power Arc 4000 Codes 10083 SVM103 A 45 00 Power Arc 4000 Codes 10200 10244 SVM103 B 45 00 ProCut 60 Single Phase Codes 9819 10118 SVM104 A 45 00 V300 PRO Codes 9934 10131 SVM105 A 45 00 LN 7 GMA Codes 9168 9931 SVM106 A 45 00 RANGER 8 Codes 9972 101 10 SVM107 A 45 00 DC600 Codes 9773 9910 SVM108 A 45 00 POWER WAVE 350 500 Codes 10104 10155 SVM109 A 65 00 RANGER 9 Codes 9975 9976 SVM110 A 45 00 SP250 Codes 9402 10002 SVM111 A 45 00 POWER WAVE 450 Codes 10105 10195 SVM112 A 65 00 WELDAN POWER 125 Codes 10158 10160 SVM113 A 45 00 LN25 Codes 9218 10150 SVM114 A 45 00 SP255 Codes 10164 10165 SVM115 A 45 00 Idealarc CV 300 Codes 9456 10181 SVM116 A 45 00 Wire matic 250 Codes 9799 10004 SVM117 A 45 00 Square Wave TIG 355 Codes 9951 9955 SVM118 A 45 00 Wire matic 255 Codes 10166 10167 SVM119 A 45 00 Ranger 10 LX Codes 9975 9976 SVM120 A 45 00 TOTAL SHIP MANUALS TO Name Address Phone 50 267 3 96 Now Available 12th Edition The Procedure Handbook of Arc Welding With over 500 000 copies of previous editions published since 1933 the Procedure Handbook is considered by many to be the Bibl2. jou Aew 31 SI Weep SUL 310 76011 9 00000000 00000000 HSVHd WISONIS 09 L 2 OHd si JI speued ou Jo uo SU WvHoOVIGd J 22 July96 INPUT SUPPLY CONNECTION DIAGRAM FOR DUAL VOLTAGE MACHINE NOTE MACHINES ARE SHIPPED FROM FACTORY CONNECTED LINK POSITIONS 60HZ FOR 575 VOLTS AWARNINC EAP AE operate with covers removed Disconnect input power before servicing 2 10 AWG ONLY Do not touch electrically live parts Only qualified persons should install use or service this equipment LINK POSITIONS can kill 460 V 6082 CONNECT L1 amp L2 INPUT SUPPLY LINES TO INPUT SIDE OF THE TERMINAL BLOCK AS SHOWN TORQUE TO 16 IN LBS
3. Do nottouch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja 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 pi ces sous tension Isolez vous du travail et de la terre 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 Isole se da e terra e REPOR NTWSHIELTFSU BEER 94 e e EC EUEEALT HIER Xe sup nisle e AXE Ys ola Ju Gu cus uil slo gual Si eani stay ag gh ri aet poc ule Keep flammable materials away Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflam veis bem guarda dos HdEXIHITU CIE EA e i DAMS eclss S88 AIX ng way OI A AL al gll e Wear eye ear and bod
4. CONNECT TERMINAL MARKED TO edeoup PER NATIONAL ELECTRICAL CODE REMOVE HEX NUTS AND POSITION LINKS AS SHOWN REPLACE AND TIGHTEN ALL HEX NUTS M17447 THE LINCOLN ELECTRIC CO CLEVELAND OHIO U S A FIGURE 1 Dual Voltage INPUT SUPPLY CONNECTION DIAGRAM NOE FOR TRIPLE VOLTAGE MACHINE _ NOTE MACHINES ARE SHIPPED FROM FACTORY CONNECTED FOR 440 OR 460 VOLTS USE FERRULE AWARNING Do not operate with covers removed dio AWG ONLY Disconnect input power before servicing 230 V 60HZ o Do not touch electrically live parts Only qualified persons should install HIGH VOLTAGE y f can kill use or service this equipment CONNECT L1 amp L2 INPUT SUPPLY LINES TO INPUT SIDE 208 V 60HZ LIN POSITIONS OF THE TERMINAL BLOCK AS SHOWN TORQUE TO 16 IN LBS m CONNECT TERMINAL MARKED TO GROUND PER NATIONAL ELECTRICAL CODE REMOVE HEX NUTS AND POSITION LINKS AS SHOWN REPLACE AND TIGHTEN ALL HEX NUTS TER M15698 THE LINCOLN ELECTRIC CO CLEVELAND OHIO U S A FIGURE 1 Triple Voltage 23 May96 CUTTING TORCH CONNECTION DIAGRAM TM FOR MAGNUM PCT 60 PLASMA TO
5. Strip Required for 10 5 3mm Wire Place Ferrule S19117 1 Over Wire as Shown Before Insertion into Machine Terminal Block For 10 5 3mm AWG Wire Only RECOMMENDED WIRE SIZE FOR PRO CUT INPUT CONNECTIONS Based on U S National Electrical Code Ambient Temperature 30 C or Less Wire Size Copper 75 C Rated Input Voltage Less than 230 8 8 4mm 230 8 8 4mm 460 10 5 3mm Greater than 460 10 5 3mm 2 Input Wires 1 Grounding Wire 10 5 3mm 10 5 3mm 10 5 3mm 10 5 3mm A CAUTION The frame of the machine must be grounded A ground terminal marked with the symbol H located at the left side of the input box is provided for this pur pose See the U S National Electrical Code for details on proper grounding methods Follow other grounding instructions per the paragraph under High Frequency Interference Protection On multiple voltage input machines be sure the reconnect panel is connected per the following instructions for the voltage being supplied to the machine See Figure 1 in the back of this manual Failure to follow these instructions can cause imme diate failure of machine components The PRO CUT is shipped connected for the highest nameplate input voltage To change this connector for a different input voltage reconnect the power straps to their respective terminals corresponding to the input voltage used Fuse the input circuit with the recommen
6. 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 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 main tained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Oylinders should be located Away from areas where they may be struck or subjected to physical damage A safe distance from plasma cutting or gouging arc weld ing operations and any other source of heat sparks or flame Never allow any part of the electrode torch or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas oylin ders associated equipment and
7. conductors on the back of the board If there is no visible damage to the PC board install a new one and see if this remedies the problem If the problem is remedied reinstall the old PC board to see if the problem still exists If it does no longer exist with the old PC board 1 Check the PC board harness conductor pins for corrosion contamination or looseness 2 Check leads in the plug harness for loose or intermittent connection If PC board is visibly damaged electrically compo nents burned copper traces opened or damaged before possibly subjecting the new PC board to the same cause of failure check for possible shorts opens or grounds caused by 1 Frayed or pinched lead insulation 2 Poor lead termination such as a poor contact or a short to adjacent connection or surface 3 Two or more leads shorted together 4 Foreign matter or interference behind the PC boards If PC board is visibly damaged mechanically such as a part vibrated off or was crushed inspect for cause then remedy before installing a replacement PC board If there is damage to the PC board if replacing PC board corrects problem return it to the local Lincoln Electric Field Service Shop 21 sup SAID 3uswure2ejdai e SUR AUM apisul 5 si sem sped sim Aq
8. higher preheat tem perature may be required The recommended mini mum preheat temperature for plate thickness up to 1 2 inch 12 7m is 70 F 21 1 USER RESPONSIBILITY Because design fabrication erection and cutting vari ables affect the results obtained in applying this type of information the serviceability of a product or struc ture is the responsibility of the user Variation such as plate chemistry plate surface condition oil scale plate thickness preheat quench gas type gas flow rate and equipment may produce results different than those expected Some adjustments to procedures may be necessary to compensate for unique individ ual conditions Test all procedures duplicating actual field conditions INSTALLATION SAFETY PRECAUTIONS Read the safety precautions at the beginning of this Operator s Manual before proceeding Only personnel that have read and under stood this Operators Manual should install and operate this equipment Machine must be connected to system ground per any national local or other applicable electrical codes The power switch is to be in the OFF position when connectiong power cord to input power A WARNING TURN THE INPUT POWER OFF USING THE DISCONNECT SWITCH AT THE FUSE BOX BEFORE ATTEMPTING TO CONNECT THE INPUT POWER LINES Only qualified personnel should perform this installa tion Turn the power switch on the PRO CUT off before connecting or disconne
9. machine HOW TO USE THIS GUIDE Carefully read through each applicable section listed on the following pages Remember that most problems are caused by improp er setup such as switch settings control settings etc If you believe the set up is correct and the trouble still exists first check for the obvious input power blown fuses loose PC board connectors broken wires and the like The sections listed on the following pages are intended to help you find the less obvious sources of trouble SYMPTOM CHECK No LED s light when the power switch is turned on Check the input power to be sure it is on Check the power line fuses and machine connection Replace line switch TORCH WILL NOT LIGHT Low air pressure results in a no start condition The MACHINE ON LED is lit but there is no Air Pressure LED must be lit when air is response when the trigger is pulled flowing Set the machine in purge mode The air will turn on Set the regulator on the back of the machine for 60 psi minimum If the AIR PRESSURE LED does not light raise the pressure slightly If the inlet pressure is greater than 75 psi and the LED is not lit when air is flowing there is a leak or the air filters in the regulator assembly are clogged Check the SAFETY LED If it is lit check the torch consumables and press the SAFETY RESET button Check the air supply to the machine If the air does not flow the machine will not start Che
10. welding applications speeds and costs Practice materials exercises questions and answers are suggested for each lesson 528 pages well illustrated 6 x 9 size bound in simulated gold embossed leather 5 00 postage paid U S A Mainland Need Welding Training The Lincoln Electric Company operates the oldest and most respected Arc Welding School in the United States at its corporate headquarters in Cleveland Ohio Over 100 000 stu dents have graduated Tuition is low and the training is hands on Lincoln Welding School 22801 St Clair Ave Cleveland Ohio 44117 1199 For details write and ask for bulletin ED 80 or call 216 383 2259 and ask for the Welding School Registrar Lincoln Welding School BASIC COURSE 700 00 5 weeks of fundamentals lOrders of 50 or less before discount or orders outside of North America must be prepaid with charge check or money order in U S Funds Only IPrices include shipment by 4th Class Book Rate for U S A Mainland Only Please allow up to 4 weeks for delivery IUPS Shipping for North America Only All prepaid orders that request UPS shipment please add 5 00 For order value up to 49 99 10 00 For order value between 50 00 amp 99 99 15 00 For order value between 100 00 amp 149 00 For North America invoiced orders over 50 00 amp credit card orders if UPS is requested it will be invoiced or charged to you at cost Outsid
11. 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 Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s rec ommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations PLASMA ARC can injure i 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 3 may be dangerous SR 8 a Electric current flowing through any con d lized Electri d A Magnetic Fields EMF Cutting or gouging current creates EMF fields around torch cables and cutting machines 8 b EMF fields may interfere with some pacemakers so opera tors having a pacemaker should consult their physician before cutting or gouging 8 c Exposure to EMF fields during cutting or gouging may have other health effects which are now not known 8d All operators should use the following procedures in order to minimize exposure to EMF fields from the cutting or gouging circuit 8 d 1 Route the torch and w
12. blinking If cutting tried with air pressure less than 60 psi 413 kPa while air is flowing the machine will wait for air pressure to become greater than 60 psi 413 kPa Light blinking alternately with OUTPUT ON Light started blinking during cutting or gouging There is an overcurrent condition caused by a surge of current the machine was not designed to handle Release the trigger and resume cutting or gouging Light blinking with THERMAL light on 49 Normal There is a problem with the microprocessor replace the Control PC board Wait for machine lights to stop blinking Normal conditions are purge preflow postflow and cutting Check consumables replace as needed Check torch cable to see if it is punctured or cut No air connected to machine air pressure set too low or air leak in system Pilot arc duty cycle has been exceeded Wait for machine lights to stop blinking If cutting or gouging with standoff more than 1 8 3 2mm at high range of machine and nozzle is accidentally touched to work shorten stickout or use Drag Cup Check consumables to see if electrode melted to nozzle Wait for machine to cool STATUS LIGHTS CONDITION SUGGESTIONS SAFETY It is possible that this light could turn on when power is first applied to machine The nozzle is not in place While cutting or gouging if the voltage between the nozzle and the work is too high it will put the machine into
13. deal of water If there is oil or a great deal of water the air must be filtered or the machine switched to nitrogen or bottled air Check the air pressure The pressure must be 60 psi 413 kPa minimum while air is flowing The Air Pressure LED must be lit The machine is overheated Allow it to cool and reset The air intakes of the machine must not be blocked or this will become a nuisance The Fault circuit monitors the torch to see if it is shorted as well as internal machine failures Check the torch consumables to see if they are melted together or are simply touching each other Tighten clean or replace See Suggestion for Extra Utility from the PRO CUT System Check the torch cab le to see if it is cut or punctured Replace Turn off the machine and turn it back on If the FAULT LED will not stay off when you try to cut again and there is no problem with the torch then something has failed in the machine and the machine should not be left on 4a Check electrode to pilot for short 4b Check air flow 4c Check the power board During preflow there should be no voltage between work and electrode and at end of preflow open circuit voltage should be present Replace if bad Replace control PC board Replace control PC board The pilot arc duty cycle has been exceeded The machine will cool down and the lights will quit blinking in about 20 seconds The pilot arc is limited to 20 out of 80 seconds except
14. of the machine before tightening cleaning or replacing consumables e Check the assembly of the torch consumables If they are not properly in place then the machine will not start 12 After the problem is found reset the machine by pressing the Safety Reset button It is possible for electrical noise to trip the safety cir cuit on rare occasions This should not be a regular occurrence f the machine does not reset or continues to trip consult the Troubleshooting Section Pilot Arc Discussion The PRO CUT has a smooth continuous pilot arc The pilot arc is only a means of transferring the arc to the workpiece for cutting Repeated pilot arc starts in rapid succession is not recommended as these starts will generally reduce consumable life Occasionally the pilot arc may sputter or start intermittently This is aggravated when the consumables are worn or the air pressure is too high Always keep in mind that the pilot arc is designed to transfer the arc to the work piece and not for numerous starts without cutting Procedure Recommendations When properly used plasma arc cutting or gouging is a very economical process Improper use will result in a very high operating cost General Follow safety precautions as printed inside the operating manual and on the machine Use the drag cup when hand cutting at medium or high output Use the proper cutting or gouging procedures referred t
15. Never use the smallest 035 0 9mm orifice size at outputs above the yel low range because it will be quickly destroyed The PRO CUT 60 is capable of operation with a 50 ft 15 2m plasma torch Pilot arc operation may be slightly degraded with this torch installed Sputtering may occur after the pilot arc is established and occa sionally the pilot arc may not light after the trigger is depressed Keep in mind that the condition of the consumables and air pressure level have a large impact on pilot arc ignition Neither cutting performance nor machine reliabili ty will be lessened by this condition A WARNING ELECTRIC SHOCK CAN KILL Turn off machine at the disconnect switch on the front of the machine before tightening cleaning or replacing consumables 14 MAINTENANCE PROCEDURE ROUTINE MAINTENANCE WARNING ELECTRIC SHOCK KILL BEFORE PERFORMING ANY MAINTE NANCE THAT REQUIRES OPENING THE CASE OF THE POWER SOURCE Disconnect input power to this machine at the Disconnect switch Do not touch electrically live parts or internal wiring Only qualified personnel should service this machine Keep the cutting or gouging area and the area around the machine clean and free of com bustible materials No debris should be allowed to collect which could obstruct air flow to the machine Every few months blow the dust off the air intakes and louvers with compressed air Also blow off the com
16. PRO CUT single Phase IM399 D PLASMA CUTTING SYSTEM For use with all code number machines thru 10394 RETURN TO MAIN INDEX 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 4 4 4 4 v This manual covers equipment which is obsolete and no longer in production by The Lincoln Electric Co Specifications and availability of optional features may have changed OPERATOR S MANUAL ES ISO 9002 CERTIFICATE NUMBER men LINCOLN amp World s Leader in Welding and Cutting Products ELECTRIC Premier Manufacturer of Industrial Motors 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 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 recom
17. RCH Do not operate with covers removed Disconnect input power before servicing Do not touch electrically live parts Only qualified persons should install HIGH VOLTAGE use or service this equipment can kill AMPHENOL CONNECTOR NS STRAIN RELIEF CLAMP RN CABLE BOOT m di ADAPTER GAS LINE LEAD PILOT BOLT WORK WORK LEAD PRO CUT 60 POWER SOURCE THE LINCOLN ELECTRIC CO CLEVELAND OHIO U S A 1 DISCONNECT INPUT POWER TO THE PRO CUT AND TURN MACHINE POWER SWITCH OFF 2 INSERT TORCH CABLE THROUGH CABLE BOOT TURN AND LOCK STRAIN RELIEF CLAMP ONTO BOLT 3 CONNECT PILOT LEAD 4 PLACE GAS LINE FITTING ON ADAPTER AND SCREW TIGHT 5 ATTACH AMPHENOL CONNECTOR 7 26 91C 19941 FIGURE 2 May96 24 NOTES LINCOLN ELECTRIC SERVILE MANUALS Now Available The following Service Manuals ORDER FROM Lincoln Electric Company 22801 St Clair Ave Cleveland Ohio 44117 1199 LINCOLN amp These are comprehensive single sources of information relative to Installation Operation Maintenance Accessories Theory of Operation Replacement Parts Electrical Diagrams and Extensive Troubleshooting Technical Service Group Customer Service Dept All orders must be pre paid US Funds Only Please allow up to 4 weeks for delivery Make checks or Money Orders payable to the Lincoln Electric Company
18. SAFETY If the cable is punctured or cut it can trip the SAFETY The torch may be overheated There is a thermal sensor in thehand held torch heads to protect it during abusive use It will not trip in normal use even if it is abused heavily 20 If machine can be reset it is OK to continue operation Securely fasten nozzle in place By pressing reset the machine will be functional This occurs most often when the consumables are wearing out By removing the hafnium that builds up on the inside of the nozzle it is possible to extend the life of the consumables By pressing reset it will clear the SAFETY When cutting is tried again the machine will either go into FAULT or SAFETY until that time the machine will not indicate a malfunction condition Wait for the torch to cool down and reset the safety circuit Read the procedures section of this manual for instruction in proper cutting technique PROCEDURE FOR REPLACING PC BOARDS A WARNING _ ELECTRIC SHOCK CAN KILL BEFORE PERFORMING ANY MAINTE NANCE THAT REQUIRES OPENING THE CASE OF THE POWER SOURCE Disconnect input power to this machine at the Disconnect switch Do not touch electrically live parts or internal wiring Only qualified personnel should service this machine Before replacing a PC board which is suspected of being defective visually inspect the PC board in ques tion for any damage to any of its components and
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20. bles Autant que possible l installation et l entretien du poste seront Des gouttes de laitier en fusion sont mises de l arc de P WE effectu s par un lectricien qualifi soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan Avan fair ravaux l interieur rancher talons sans revers et chaussures montantes ant de faires des travaux l interieur de poste la debranche l interrupteur la boite de fusibles Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les Garder tous les couvercles et dispositifs de s ret leur place Mar 93 TABLE OF CONTENTS Page Safety Precautions Red nn in eB INT 2 4 Introductory Information cott rtr eet paredes eu gue 6 7 Product Descriptio Nissi sanaaa eine tailles 8 Preheat Temperature for Plasma Cutting 1 ennt 8 User Responsibility iii 8 ea 9 11 Safety Precautions iii 9 LOCIVO PP EEROR N E E AEE E E AN 9 High Frequency Interference Protection 9 Electrical Input COnfFlectlOn soie nn ise esti eek eee vee tedden E dde 10 Air Input Connections iii 11 Output Connections 2 25 2 5 1 ie hn Rie TRUE HERE D REIR eee 11 Torch Connection eret ordei Ree ec En
21. 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 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 PR CAUTIONS DE S RET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR 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 Relier I rre le chassi nformemen de soudeur et des aides contre le rayonnement de l arc elier 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 c Prot ger l autre personnel travaillant proximit au DT bonne mise la terre soudage l aide d crans appropri s et non inflamma
22. ch 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 Model Name amp Number Code amp Serial Number Date of Purchase Whenever you request replacement parts for or information on this equipment always supply the information you have recorded above Read this Operators Manual completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection The level of seriousness to be applied to each is explained below A WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life A CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment SPECIFICATIONS Type 208 230 460 1 60 230 460 1 60 460 575 1 60 Input Frequency Output Rating Pilot Current Pilot Duty Cycle Current Range Maximum OCV Normal OCV In
23. ck the operation of the air solenoid by switching the machine to PURGE The air should begin to flow and if the pressure is suffi cient the AIR PRESSURE LED will light Return to RUN mode If air does not flow check the solenoid by applying 115 VAC to its input leads If it is bad replace the solenoid or else replace the control board The air begins to flow the OUTPUT ON LED lights Check the torch consumables to be sure they for a brief period but no arc is established are in tight not dirty or greasy and in good shape Replace the consumables if necessary Check that CR2 engages Check for high frequency at the spark gap Check the high frequency spark gap located inside the right panel of the machine It should be set at 060 1 52mm DISCONNECT ALL POWER BEFORE ADJUSTING THE HIGH FREQUENCY CIRCUIT Blow off the components in the upper compart ment with compressed air Check pilot to 391 for 2 ohm resistance Check 2 ohm 300 watt resistor Replace Control PC Board SYMPTOM CHECK The arc starts but sputters badly The THERMAL LED is lit The FAULT LED is blinking The FAULT LED is lit Alternating AIR FAULT LED lights The OUTPUT ON and FAULT LED s blink in alternating order Airflow will not shut off Check the torch consumables to be sure they are tight not dirty or greasy and in good shape Replace if necessary Check air supply for oil or a great
24. cting output cables Connect the PRO CUT grounding terminal located on the side of the case back to a good electrical earth ground LOCATION Place the PRO CUT where clean cooling air can freely circulate in through the front intake and out through the rear louvers Dirt dust or any foreign material that can be drawn into the machine should be kept at a minimum Failure to observe these precau tions can result in excessive operating temperatures and nuisance shutdown of the machine Before plan ning the installation read the section entitled High Frequency Interference Protection A source of clean dry compressed air or nitrogen must be supplied to the PRO CUT Oil in the air is a severe problem and must be avoided The supply pressure must be between 70 and 120 psi 482 and 827 kPa The flow rate is approximately 4 7 cfm 133 I min Failure to observe these precautions could result in excessive operating temperatures or damage to the torch HIGH FREQUENCY INTERFERENCE PROTECTION Since the spark gap oscillator in the high frequency generator in the machine is similar to a radio transmit ter improper machine installation can result in radio and TV interference or problems with nearby electron ic equipment Radiated interference can develop in the following four ways Direct interference radiated from the machine Direct interference radiated from the cutting leads Direct interference radiated from feedback i
25. ded super lag fuses Choose an input and grounding wire size according to local codes or use the Input Connection table Delay type circuit breakers may be used in place of fuses Using fuses or circuit breakers smaller than recommended may result in nuisance tripping from machine inrush currents even if not cutting or gouging at high currents Also called inverse time or thermal magnetic circuit breakers circuit breakers which have a delay in tripping action that decreases as the magni tude of the current increases A WARNING CYLINDER may explode if damaged Keep cylinder upright and chained to a fixed support Keep cylinder away from areas where it may be damaged Never lift equipment with cylinder attached Never allow the cutting torch to touch cylinder Keep cylinder away from live electrical circuits Maximum inlet pressure 120 psig 827 kPa AIR INPUT CONNECTIONS A source of clean compressed air or nitrogen must be supplied to the PRO CUT The supply pressure must be between 70 and 120 psi 482 and 827 kPa The flow rate is approximately 4 7 cfm 133 l min Oil in the air is a very severe problem and must be avoided Remove the plastic thread protector from the regulator input port located on the back of the machine Use suitable gas connection fitting to make the connection to the available air supply The input port is a 1 4 411 6 3 mm NPT thread Tighten the ai
26. e of the arc welding industry This printing will go fast so don t delay Place your order now using the coupon below The hardbound book contains over 750 pages of welding information techniques and procedures Much of this material has never been included in any other book A must for all welders supervisors engineers and designers Many welding instructors will want to use the book as a reference for all students by taking advantage of the low quantity discount prices which include shipping by 4th class parcel post 15 00 postage paid U S A Mainland How To Read Shop Drawings The book contains the latest information and application data on the American Welding Society Standard Welding Symbols Detailed discussion tells how engineers and draftsmen use the short cut language of symbols to pass on assembly and welding information to shop personnel Practical exercises and examples develop the reader s ability to visualize mechanically drawn objects as they will appear in their assembled form 187 pages with more than 100 illustrations Size 8 1 2 x 11 Durable cloth covered board binding 4 50 postage paid U S A Mainland There is a 10 discount on all orders of 50 00 or more for shipment ai at one time to one location New Lessons in Arc Welding Lessons simply written cover manipulatory techniques machine and electrode characteristics related subjects such as distortion and supplemental information on arc
27. e U S A Mainland order must be prepaid in U S Funds Please add 2 00 per book for surface mail or 15 00 per book for air parcel post shipment METHOD OF PAYMENT Sorry No C O D Orders CHECKONE Please Invoice only if order is over 50 00 1 Check or Money Order Enclosed U S Funds only O creditcad O 8 paccount No Ep pate LE JUSE THIS FORM TO ORDER Order from BOOK DIVISION The Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 Telephone 216 383 2211 or for fastest service FAX this completed form to 216 361 5901 80065 OR FREE INFORMATIVE CATALOGS Name Address Telephone Signature as it appears on Charge Card 1 Welding School I rites Code Quantity ED 80 New Lessons in Aro Welding 5 00 L Soy Information Procedure Handbook Twelfth Edition 15 00 Educational Video Information 1 ED 93 Lames F Lincoln Arc Welding Foundation Book Information 3 97 515 Ee Incentive Management 5500 M EE The American Century of John C Lco 85 30 TT Welding Preheat Calculator 300 wcs PipeWeldingChats 4 50 ED 89 AddiionalShippng Costsifany TOTALCOST El WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENC O Japanese BIR
28. eristics cutting visibility and arc stability The torch has a patented safety mecha nism which insures that the consumables are in place before cutting or gouging This is extremely important due to the high voltages involved The PRO CUT 60 comes standard with air regulator coarse air filter oil coalescing filter and pressure gauge The Pro Cut 60 comes ready to use with the torch attached Machines equipped with handheld torches are available with either 25 ft 7 6m or 50 ft 15 2m torch cable The undercarriage is standard and is shipped assembled except for the handle The machine is capable of cutting with nitrogen or air Nitrogen is used to cut aluminum and other nonfer rous metals The PRO CUT is controlled by a microprocessor based system The machine performs rudimentary self troubleshooting when powered up which aids in field servicing PREHEAT TEMPERATURE FOR PLASMA CUTTING Preheat temperature control is recommended for opti mum mechanical properties crack resistance and hardness control This is particularly important on high alloy steels and heat treated aluminum Job con ditions prevailing codes alloy level and other consid erations may also require preheat temperature con trol The following minimum preheat temperature is recommended as a starting point Higher tempera tures may be used as required by the job conditions and or prevailing codes If cracking or excessive hardness occurs on the cut face
29. gases hazardous to health Avoid breathing these fumes and gases When cutting or gouging keep your head out of the fumes Use enough ventila tion 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 expo sure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventila tion In confined spaces or in some circumstances out doors a respirator may be required Additional precau also required when welding on galvanized steel Do not use plasma arc cutting or gouging in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating products Gases used for plasma cutting and gouging can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employ er s safety practices 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 cove
30. in special circumstances such as cutting expanded metal See the section on expanded metal in the Operating Section Check harness 1J7 C2 and 3J7 H6 SYMPTOM CHECK The SAFETY LED is lit No OCV when 2 and 4 are closed 18 The machine will not operate The machine senses that the nozzle is not in place or the operator could be exposed to dangerous volt ages if the machine were allowed to operate Check the nozzle to be sure it is tightly in place Check the torch consumables to see if they are melted together or are simply touching each other Tighten clean or replace See Suggestion for Extra Utility from the Pro Cut System Check the torch cable to see if it is cut or punc tured Replace Check to see that the torch is hooked to the machine properly Push the SAFETY RESET button the LED should go out If the LED does not go out the thermal sensor in the torch head has actuated Note that the thermal sensor exists in the hand held torches but not the machine or robotic torches This sensor prevents the torch from melting and should not trip in normal operation Wait several minutes until the torch head is cool and press the reset button If the LED does not go out check step 2 again before proceeding Read the procedures section of this manual for instruction in proper cutting technique This circuit rarely trips on power up or because of noise If the circuit can be reset it is Ok to con
31. lation 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 piercing safety clothing 1 j Also see Items 4c and 6 2 b 2 C Apr ARC RAYS can burn 2 a Use safety glasses and a shield with the prop er filter and cover plates to protect your eyes from sparks and the rays of the arc when per forming or observing plasma arc cutting or gouging Glasses headshield and filter lens should conform to ANSI Z87 standards Use suitable clothing including gloves made from durable flame resistant material to protect your skin and that of your helpers from the arc rays Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal 93 Where compressed gases are to be used at the job site spe When not cutting or gouging make certain no part of the elec Do not cut or gouge tanks drums or containers until the prop Vent hollow castings or containers before heating cutting or Do nor fuel engine driven equipment near area where plasma FUMES AND GASES 49 be dangerous 3 a Plasma cutting or gouging may produce fumes and
32. means of extending nozzle life Sometimes a small piece of material breaks off the electrode and bridges the gap between the nozzle and the electrode In a competitive unit this would often result in the destruction of the elec trode and nozzle due to overheating This will result in the tripping of the PRO CUT safety circuit When this happens turn the power off remove the nozzle and scrape any debris from its inside cavity with a piece of sturdy wire or a suitable drill bit Replace the nozzle turn on the power and continue cutting The electrode has a hafnium insert at the tip which greatly prolongs the life of the consumable When that insert has been consumed the machine will automatically turn off output and lock up in FAULT At this point replace the electrode and the nozzle it is not recommended to continue cutting with an elec trode that has consumed all of its hafnium Use of the nozzle with the largest orifice size that pro duces acceptable cutting results will maximize con sumable life Procedures given are all based on a 042 1 0mm orifice size Smaller orifice sizes con strict the arc more raising the energy density and therefore the temperature Larger orifice sizes have an opposite effect Small orifice nozzles run hotter and wear faster than large orifice nozzles but pro duce a finer cut with less kerf width There is a cer tain current where each orifice size becomes unsta ble because it runs too hot
33. mended that you pur chase 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 QUALIFIED INDIVIDUALS 1 e ELECTRIC SHOCK can kill 1 a The electrode and work or ground circuits are electrically hot when the power source is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands When the power source is operating voltages in excess of 250 volts are produced This creates the potential for serious electrical shock potentially even fatal Insulate yourself from work and ground using dry insulation When cutting or gouging in damp locations on metal frame work such as floors gratings or scaffolds and when in posi tions such as sitting or lying make certain the insulation is large enough to cover your full area of physical contact with work and ground Always be sure the work cable makes a good electrical con nection with the metal being cut or gouged The connection should be as close as possible to the area being cut or gouged Ground the work or metal to be cut or gouged to a good elec trical earth ground 1 f Maintain the plasma torch cable and work clamp in good 1 9 1 h safe operating condition Replace damaged insu
34. natmen von Schweibrauch Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fuma a Use ventila o e exhaust o para remover fumo da zona respirat ria etai ADP5o5UtRE e c EUR Bit Fi S XACE E 247 MASH A8 2 A717 587E ASIA ias dial sai Aie Ajo ell Qd ult ee jud abil e Gall bacs 3 Jaial vdi uu oe Quad Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v lli Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas opere com os paineis abertos ou guardas removidas ES LEWC EU CRRRIARRARS Ro endo Sel AE Asal Abiyi ats Vil jal lia Ja ve gle Sual gt Aaaa WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATEN O Japanese it es BIR LEIA E COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANCA DO EMPREGADOR SRM OBUOX HD OHRBEE lt M MA ETISRIUCEFSU CUCRITEOSSXSUEL HS CF e
35. nto the power lines 4 Interference from reradiation of pickup by ungrounded metallic objects Keeping these contributing factors in mind installing equipment per the following instructions should mini mize problems 1 Keep the machine power supply lines as short as possible 2 Keep the work and torch leads as short as possi ble and as close together as possible Lengths should not exceed 50 ft 15 2 m Tape the leads together when practical Be sure the torch and work cable rubber cover ings are free of cuts and cracks that allow high frequency leakage Keep the torch in good repair and all connections tight to reduce high frequency leakage 5 Keep all access panels and covers securely in place NOTE The machine frame MUST also be grounded see CAUTION under Input Connection sec tion The work terminal ground does not ground the machine frame When the machine is enclosed in a metal build ing several good earth driven electrical grounds around the periphery of the building are recommended 6 Failure to observe these recommended installation procedures may cause radio or TV interference prob lems and result in unsatisfactory cutting or gouging performance resulting from lost high frequency power INPUT CONNECTIONS A WARNING ELECTRIC SHOCK can kill Disconnect input power before proceeding Have a qualified electrician make the input connections Be sure the voltage pha
36. o in procedures guideline Use the shield cup with mechanized torches or when hand cutting at low output Thin Gauge Sheet Metal Output set below mid range The torch should be dragged on the metal sur face touching the nozzle lightly to the surface after piercing a hole Current control should be set in the yellow range only The S24114 Drag Cup should not be used at very low outputs It may cause erratic arc action The 035 0 8mm nozzle may be used for a fine cut Larger nozzles will work and provide longer life at the expense of a larger cut Do not allow the torch cable or body to contact hot surface The best quality cut is obtained by reducing the current to a level that is adequate for the maxi mum travel speed Aluminum copper and other nonferrous metals typically require more current than the same thickness of steel Treat these as a thicker sec tion of steel if good results are not obtained Expanded Metal Output set near mid range Cut it as you would light gauge sheet metal Expanded metal is pilot arc intensive After about 30 seconds of cutting the pilot arc will change from a bright continuous arc to a discon tinuous one which will sputter slightly It will stay in this mode as long as metal has been cut in the previous 5 seconds If metal is not cut in the previous 5 seconds the arc will shut off and the machine will go into postflow f the trigger is continuously p
37. ork 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 Connect the work cable to the workpiece as close as possible to the area being cut or gouged Do not work next to cutting power source Apr 93 PR CAUTIONS DE S RET Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher 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 p
38. orte 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 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 du corps Un coup d arc peut tre plus s v re qu un coup de soliel donc 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 chauf fement 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 c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c
39. ponents in the upper compart ment with compressed air Check the air regulator filters to be sure they do not become clogged The first stage of the air filter on the machine is self draining and will stop most of the water in the air line The sec ond stage of the filter is also self draining and will stop almost all of the oil in the line as well as particulate matter Both stages will drain auto matically when the flow rate changes rapidly 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 periodically and relieve any so as not to restrict the flow of air to the torch A WARNING ELECTRICAL SHOCK CAN KILL Turn off machine at the disconnect switch at the back of the machine before tightening cleaning or replacing consumables Change consumables as required 15 TROUBLESHOOTING PROCEDURES A WARNING ELECTRIC SHOCK CAN KILL BEFORE PERFORMING ANY MAINTE NANCE THAT REQUIRES OPENING THE CASE OF THE POWER SOURCE Disconnect input power to this machine at the Disconnect switch Do not touch electrically live parts or internal wiring Only qualified personnel should service this
40. put Power tandard Voltages Current Other Voltages Current Idle Current Idle Power Power Factor Q Rated Load Net Weight w 25 ft 7 6 m Cable w 50 ft 15 2 m Cable Dimensions Hx Wx D includes lift bail and undercarriage K1362 1 Handheld Torch with 25 ft 7 6m Cable K1362 2 Handheld Torch with 50 ft 15 2m Cable K1361 1 Handheld Torch with 25 ft 7 6m Cable K1361 2 Handheld Torch with 50 ft 15 2m Cable K1362 3 Handheld Torch with 25 ft 7 6m Cable K1362 4 Handheld Torch with 50 ft 15 2m Cable K1362 5 Robotic Torch with 50 ft 15 2m Cable K1362 6 Machine Torch with 50 ft 15 2m Cable K1362 7 Robotic Torch with 50 ft 15 2m Cable K1362 8 Machine Torch with 50 ft 15 2m Cable K871 1 25Ft 7 6m Cable amp K871 2 50Ft 15 2m Cable Magnum PCT 60 Air Cooled Torch 60 Hz 60 Amps 115 volts 6096 Duty Cycle 60 Amps 115 volts Maximum Output 45 Amps 115 volts 10096 Duty Cycle 22 5 amps 25 20 seconds out of 80 seconds 25 60 Amps 282 Volts 250 Volts 208 230 460 1 60 K1362 1 2 5 6 50 45 23 Amps 230 460 1 60 460 575 1 60 K1362 3 4 7 8 K1361 1 2 45 23 Amps 23 18 Amps 4 5 amps 230V Maximum 0 7 kW Maximum 0 65 322 lbs 146 kg 329 165 149 kgDimensions H x W x D 34 x 19 x 22 864mm x 483mm x 559mm PRODUCT DESCRIPTION The PRO CUT 60 is a constant current single range continuous control plasma cutting system It provides excellent starting charact
41. r fitting to prevent leakage but do not overtighten The use of Teflon tape to seal the connection is recommended Nitrogen from cylinders may be used with this machine The cylinder of nitrogen gas must be equipped with a pressure regulator No more than 120 psi 827 kPa may be supplied to the regulator on the machine Install a hose between the regulator on the gas cylinder and the gas inlet on the machine OUTPUT CONNECTIONS A WARNING HIGH FREQUENCY SHOCK CAN CAUSE INJURY OR FALL Keep the cutting torch and cables in good condition Secure yourself in position to avoid a fall e Torch Connection The PRO CUT comes factory equipped with a cutting torch Pictures of the torch along with the required replace ment parts are shown in the parts lists in the back of this manual The ends of the cable to be connected to the power source are unique Follow the applicable instructions as given in Figure 2 in the back of this manual Work Cable and Clamp Installation Work cable NS Work clamp gt Attach the work clamp to the work cable which extends from the front of the machine as shown Tighten nut and bolt securely OPERATING INSTRUCTIONS Sequence of events A Turn on the line power B Connect the air supply to the machine C Turn the power switch on The green Power On LED should begin to glow The fan should start If the Safety LED is glowing push the Safety Reset bu
42. r 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 cial precautions should be used to prevent hazardous situa tions Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equip ment being used trode circuit is touching the work or ground Accidental con tact can cause overheating and create a fire hazard er steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above gouging They may explode cutting or gouging 4 g Sparks and spatter are thrown from the plasma arc Wear safety glasses ear protection and oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when cutting or gouging out of position or in confined places Always wear safety glasses with side shields when in a cutting or gouging area
43. rag the nozzle in the yellow range The use of the Drag Cup at low currents in the yellow range may cause problems Proper use of the Drag Cup is the best way to get maximum nozzle and consumable life Use the proper machine setting Running the System at maximum output will not produce the best cutting performance in most situations Use the proper cutting or gouging procedures referred to in procedures guideline Use the nozzle with the largest orifice size that gives an acceptable cut This will improve parts life Never use the 035 0 8mm nozzle at out puts above the yellow range Suggestions for Extra Utility from the PRO CUT System In some cases where moderate or thin sections are being cut higher air pressure may give bet ter consumable life At pressures about 80 psi 551 kPa the pilot arc may sputter This may be an annoyance but it will not damage the torch or power source 60 psi 413 kPa mini mum while air is flowing is the recommended pressure because it is the minimum necessary to provide proper cooling in all situations Feel free to experiment with higher pressures not to exceed 120 psi 827 kPa at the regulator input The PRO CUT will cut with consumables that are worn considerably Many competitive systems require replacement consumables long before a PRO CUT system does This is because of the solid state current regulation that the PRO CUT has Also the safety reset circuit provides a
44. ressed and released to obtain the bright pilot arc for long periods of time the machine will go into pilot arc duty cycle limit This is a 20 seconds out of 80 seconds pilot duty cycle The pilot arc is dis abled in the limit period Pilot arc duty cycle limit is indicated by alternately flashing OUT PUT ON and FAULT LED s Placing a thin piece of scrap sheet metal above the area to be cut and cutting through both can make the job easier Do not allow the torch cable or body to contact hot surfaces Thick Sections of Metal Output set above mid range The best quality and consumable life will be obtained by holding the torch nozzle off the sur face about 1 8 3 2mm Output control should be sent in the red range only Do not touch the nozzle to the work or carry a long arc Use the S24114 Drag Cup to protect the torch The only reason not to use the Drag Cup when 13 the output control is in the blue or red regions is in special tight corners Always hold at least a 1 8 3 2mm standoff in those situations and use the 18817 shield cup Set the current to the minimum necessary to make the cut Use the 052 or 042 1 2 or 1 0mm nozzle size DO NOT use the 035 0 8mm nozzle Pierce the plate by slowly lowering the torch onto it at an angle of about 30 to blow the dross away from the torch tip and slowly rotate the torch to a vertical position as the arc becomes deeper Where pos
45. se and frequency of the input power is as specified on the machine nameplate 0 Before starting the installation check with the local power company if there is any question about whether your power supply is adequate for the voltage amperes phase and frequency specified on the machine nameplate Also be sure the planned instal lation will meet the any National Electrical Code and local code requirements This machine may be oper ated from a single phase line or from one phase of a two or three phase line Models that have multiple input voltages specified on the nameplate e g 208 230 460 are shipped con nected for the highest voltage If the machine is to be operated on the lower voltage it must be reconnected according to the instructions on the inside of the removable panel in the center of the rear panel Machine supply line entry provision is next to the removable panel A WARNING ELECTRIC SHOCK can kill Make certain that the input power is electrically disconnected before removing the screws that hold the removable rear panel in place 0 Have a qualified electrician connect the input leads to L1 and L2 of the terminal block in accordance with any National Electrical Code all local codes and the connection diagram located on the inside of the cover Use ferrules provided S19117 1 for 10 wire No ferrule is required for 8 wire Tighten screws to 16 in Ibs 1 8 N M See below 50 iind
46. sible start the cut from the edge of the workpiece Keep moving A steady speed is necessary Do not pause Do not allow the torch cable or body to contact hot surfaces Gouging Output set to maximum Use the gouging nozzle 518497 4 Use the Shield Cup Bring the torch slowly towards the work at about a 30 angle as if piercing the plate Blow the molten metal away from the torch Do not touch the nozzle to the work The air pressure may be raised to about 75 psi 517 kPa to aid in metal removal This process will blow a lot of molten metal and dross BE CAREFUL Blow the dross away from the torch away from the operator and away from flammable objects Do not allow the torch cable or body to contact hot surfaces Performance is similar to air carbon arc gouging with a 1 8 3 2mm carbon electrode In All Cases Do not pause when cutting or gouging the metal This is not necessary and causes opera tional difficulty Pausing at the edge of the work piece causes poor consumable life and erratic operation Always position the torch in the best way to keep dross and hot air from burning back into it Do not carry a long arc This may trip the safety or fault circuits and wears consumables rapidly Do not drag the nozzle above the mid range setting Always hold a standoff of 1 8 above mid range Use a Drag Cup where possible but only when the current is in the blue or red ranges D
47. t ne pede nieto eue Ern sno ke 11 Work Cable and Clamp 11 Operating Instructions sis 11 14 Sequence nine DICE TN OR EE RAE E 11 Pilot Are DISCUSSION e Dr ne ede irre eoe Ege ep eT apa an 12 Procedure Hecommandallons 2 cedi Hd e aiv resp re D edd eee ited 12 E 12 Thin Gauge Sheet Meldl EE nier 12 Expanded Metal tei tee og rete ee tees dares 13 Thick Sections of orc eres een ieee 13 A E 13 MALCA SES mcum 14 Suggestions for Extra Utility from the PRO CUT System 14 Maintenance Proced tes cesi ecce pied icti ae ieee 15 Routine Maintenance sisi 15 Troubleshooting ProGedures 15 21 Troubleshooting Guide su 15 18 PRO CUT 60 Status Lights Operating 19 20 Procedure for Replacing P C Boards 21 Wiring Diagram PRO GCUT 60 ocio ania redi ioco detecta A aun RERO aa 22 Input Supply Connection Diagrams sse nnne 23 Cutting Torch Connection Diagramme a ase nina dd 24 Parts MICRO rH Appendix May96 for selecting a QUALITY product by Lincoln Electric We want you hank You io take pride in operating this Lincoln Electric Company product as mu
48. tinue operation Check the continuity between pins 1 amp 3 in the plastic amp connector on the torch assembly This is the 4 pin connector that plugs into the power source If the safety circuit is working properly there will be continuity when the nozzle is in place and no continuity when the nozzle is removed When the nozzle is in place there must be continuity between pins 1 amp 3 and the torch pilot lead Replace the torch if the continu ity measurements are not as described or else replace the control board 190 VAC across H1 and H2 250V SCR PC board positive negative Check across 31 32 for 110 VAC Replace Control PC board PRO CUT 60 STATUS LIGHTS OPERATING MODES STATUS LIGHTS CONDITION SUGGESTIONS MACHINE ON Should always be on when machine is on OUTPUT ON On when there is voltage potential at the torch cutting or pilot OUTPUT ON is blinking alternately with AIR PRESSURE when power is first applied to machine If OUTPUT ON is blinking alternately with FAULT the pilot arc duty cycle is exceeded AIR PRESSURE On whenever the air pressure is above 60 psi 413 kPa there is an error condition mentioned above where air will turn on The air will turn on for a brief time when power is first applied to machine THERMAL Should normally be off If on wait for machine to cool down Light on At end of preflow machine checks to see if the torch is shorted and if it can fire the transistors Light
49. tton If there is no problem the LED will go off If there is a problem refer to Step F and the Troubleshooting Guide D Set the Purge Run switch to Purge The air should start The Air Pressure LED should be lit Adjust the air regulator for 60 psi 413 kPa minimum while air is flowing E Set the Purge Run switch to Run The air will continue to run for 20 seconds of postflow If the trigger is activated within this time period the pilot arc will immediately start F When ready to cut place the work lead on the piece to be cut place the torch near the work make certain all safety precautions have been taken and pull the trigger The air will flow for a preflow time of 2 seconds and the pilot arc will start This is true unless the machine is in postflow then the preflow time is skipped The Output ON LED will light The pilot arc will run for 2 5 seconds and shut off unless it is brought in contact with the work and the arc is transferred When the arc is transferred cutting begins Finish the cut to be made and release the trigger G When the trigger is released the arc will stop The air will continue to run for 20 seconds of postflow If the trigger is activated within this time period the pilot arc will immediately restart H If the Safety LED lights at any time check the following A WARNING ELECTRIC SHOCK CAN KILL Turn off machine at the disconnect switch on the front
50. y protection Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschutz Use prote o para a vista ouvido e corpo BH HRUBSISUCREREUCT IDESSSOSRSSR ez 119 59 s ESSAI die ule Al anas cl ysl guia e dang READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail Vermeiden Sie das Ei
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