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IM665
PRO-CUT
25
TM
September, 2004
10661
For use with machines having Code Number:
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thought-
ful operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT
READING
THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
OPERATOR'S MANUAL
Copyright © 2004 Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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Summary of Contents for Lincoln Electric PRO-CUTTM 25 IM665
- Page 1 RETURN TO MAIN MENU IM665 PRO-CUT September, 2004 10661 For use with machines having Code Number: 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 ...
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Page 2: Electric Shock Can Kill
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 &... - Page 3 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.
- Page 4 NOTES...
- Page 5 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a.
- Page 6 The code number is especially important when identifying the correct replacement parts. - Register your machine with Lincoln Electric either via fax or over the Internet. • For faxing: Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it.
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Page 7: Table Of Contents
TABLE OF CONTENTS Installation...Section A Technical Specifications ...A-1 Safety Precautions ...A-2 Select Proper Location ...A-2 Stacking...A-2 Tilting ...A-2 High Frequency Interference Protection...A-2 Input Electrical Connections ...A-2 Gas Input Connections ...A-3 Output Connections...A-3 Torch ...A-3 Operation...Section B Safety Precautions ...B-1 Description ...B-1 Preheat Temperature for Plasma Cutting...B-1 User Responsibility...B-2 Operational Features and Controls ...B-2... -
Page 8: Installation
TECHNICAL SPECIFICATIONS - PRO-CUT 25 (K1756-1) INPUT - SINGLE PHASE / 60 HERTZ ONLY Standard Voltage 115/230/1/50/60Hz Duty Cycle 20% on 115 V 60% on 115 V 100% on 230 V 35% on 115 V 60% on 230 V Current Range 12-25 Amps REQUIRED GAS FLOW RATE... -
Page 9: Safety Precautions
Read entire Installation Section before installing the PRO-CUT 25. SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK CAN KILL. • Only qualified personnel should install this machine. • Turn the input power OFF at the disconnect switch or fuse box and discharge input capacitors before working inside the equipment. -
Page 10: Gas Input Connections
WARNING • Failure to wire as instructed may cause personal injury or damage to equipment. • To be installed or checked by an electrician or qualified person only. ------------------------------------------------------------------------ Use of normal 20 amp household breakers may result in over current trips. If breaker trips occur, reduce the cutting current output until nuisance trips stop. -
Page 11: Output Connections
NOTE: When using nitrogen gas from a cylinder, the cylinder must have a pressure regulator. • Maximum psi from a nitrogen gas cylinder to the PRO-CUT 25 regulator should never exceed 150 psi. • Install a hose between the nitrogen gas cylinder regulator and the PRO-CUT 25 gas inlet CYLINDER could explode if damaged. -
Page 12: Operation
SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet clothing. • Insulate yourself from work and ground. • Always wear dry insulating gloves. FUMES AND GASES can be dangerous. •... -
Page 13: User Responsibility
USER RESPONSIBILITY Because design, fabrication, erection and cutting vari- ables affect the results obtained in applying this type of information, the serviceability of a product or struc- ture is the responsibility of the user. Variation such as plate chemistry, plate surface condition (oil, scale), plate thickness, preheat, quench, gas type, gas flowrate and equipment may produce results different than those expected. -
Page 14: Cutting Capability
CUTTING CAPABILITY The PRO-CUT 25 is rated at 25 amps, at 35% duty cycle on a 10 minute basis. If the duty cycle is exceeded, a thermal protector will shut off the output of the machine until it cools to the normal operating temperature. Figure B.1 shows the cut capacity of the PRO-CUT 25 when cutting mild steel. -
Page 15: Limitations
LIMITATIONS Do not exceed output current and duty cycle rating of machine. Do not use the PRO-CUT 25 for pipe thaw- ing. CONTROLS AND SETTINGS PRESSURE REGULATOR When preparing to cut, position the machine as close to the work as possible. Make sure you have all materials needed to complete the job and have taken all safety precautions. -
Page 16: Pilot Arc Discussion
5° - 15° Leading Angle Direction of Travel 10° - 20° Arc Lag • Use a 5° - 15° leading angle in the direction of the cut. • Finish the cut to be made and release the trigger. • When the trigger is released, the arc will stop. - The gas will continue to flow for 10 seconds of postflow. -
Page 17: Procedure Recommendations
PROCEDURE RECOMMENDATIONS When properly used, plasma arc cutting is a very eco- nomical process. Improper use will result in a very high operating cost. General - In All Cases • Follow safety precautions as printed throughout this operating manual and on the machine. •... -
Page 18: Accessories
ALWAYS USE GENUINE LINCOLN ELECTRIC ELECTRODES AND VORTECH™ NOZZLES • Only Genuine Lincoln Electric consumables yield the best cutting performance for the PRO-CUT 25. • The patented VORTECH™ nozzle provides an extra “kick” of swirl as the arc exits the nozzle which improves cutting performance. -
Page 19: Maintenance
WARNING ELECTRIC SHOCK • Have an electrician install and service this equipment. • Turn the input power off at the fuse box before working on equipment. • Do not touch electrically hot parts. • Prior to Performing preventative main- tenance, perform the following capaci- tor discharge procedure to avoid elec- tric shock. -
Page 20: Troubleshooting
HOW TO USE TROUBLESHOOTING GUIDE 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. - Page 21 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Input circuit breaker trips repeated. No Status indicators light and the fan does not operate 5 seconds after the power switch is turned on. No Status indicators light 5 seconds after the power switch is turned on, but the fan operates.
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Page 22: Torch
Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) The Pro-Cut powers up properly but there is no response when the trig- ger is pulled and only the POWER LED is lit. 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. - Page 23 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) When the trigger is pulled air begins to flow, but there is no pilot arc after at least 3 seconds. The air begins to flow and there is a very brief arc that snaps out consis- tently with repeated trigger pulls.
- Page 24 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Pilot arc starts but will not transfer when brought near work. 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.
- Page 25 Observe all Safety Guidelines detailed throughout this manual SYMPTOM The Air Low LED is lit The Safety LED is lit and steady The Thermal LED is lit TROUBLESHOOTING STATUS BOARD INDICATORS 1. Make sure there is at least 80 psi connected to the gas connec- tion at the back of the machine.
- Page 26 RHRG30120 4.7nF/4kV 2uF/400V 1500uF/250V 1500uF/250V 15K/3W 15K/3W 4.7nF/4kV 1A/250V 230VAC DIAGRAMS POT_CCW POT_CW POT_WIPER V_OUT OUTPUT TRIGGER EV2 DRIVER EV1 DRIVER TRANSFER TRANSFER SW OVLOAD SEC GND +8V_SW +12VDC_SW +12VDC +15Vrms SAFETY SEC GND OVLOAD PRO-CUT 25...
- Page 27 ● WARNING ● Spanish ● AVISO DE PRECAUCION ● French ● ATTENTION ● ● German WARNUNG ● Portuguese ● ATENÇÃO ● Japanese Chinese Korean Arabic ● ● ● ● ● ● ● ● ● ●...
- Page 28 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Spanish ● PRECAUCION French ● ATTENTION ● German WARNUNG Portuguese ● ● Japanese Chinese Korean Arabic WARNING AVISO DE ATENÇÃO...
- Page 29 • World's Leader in Welding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com...