Lincoln Electric RED-D-ARC IM648-B Operator's Manual
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Lincoln Electric RED-D-ARC IM648-B Operator's Manual

Lincoln Electric RED-D-ARC IM648-B Operator's Manual

Lincoln electric welder user manual
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RED-D-ARC
PYTHON
For use with machines having Code Numbers:
OPERATOR'S MANUAL
Red-D-Arc Spec-Built Welding Equipment
This RED-D-ARC cutter is built to RED-D-ARC Extreme Duty
design specifications by Lincoln Electric.
Safety Depends on You
This cutter 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 READING THIS MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED THROUGHOUT.
And, most importantly, think before you act and be careful.
1-800-245-3660
North America's Largest Fleet of Welding Equipment
10627, 10656
11025, 11026
IM648-B
RETURN TO MAIN MENU
June, 2003

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Summary of Contents for Lincoln Electric RED-D-ARC IM648-B

  • Page 1 OPERATOR’S MANUAL Red-D-Arc Spec-Built Welding Equipment This RED-D-ARC cutter is built to RED-D-ARC Extreme Duty design specifications by Lincoln Electric. Safety Depends on You This cutter is designed and built with safety in mind. However, your overall safety can be increased by proper installation ...

  • 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 PYTHON...
  • 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.

  • 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 Lifting and Moving ...A-2 Tilting ...A-2 High Frequency Interference Protection...A-2 Input Electrical Connections ...A-3 Input Power Cord Connector Installation...A-3 Cord Removal ...A-3 Cord Installation ...A-3 Frame Grounding ...A-4 Input Voltage Reconnection Procedure...A-4 Use on Engine Driven Power Supplies ...A-4...
  • Page 8 Maintenance ...Section D Safety Precautions ...D-1 Input Filter Capacitor Discharge Procedure ...D-1 Routine Maintenance...D-2 Periodic Maintenance ...D-2 Troubleshooting ...Section E Safety Precautions...E-1 How to Use Troubleshooting Guide...E-1 Troubleshooting Guide ...E-2 Wiring Diagrams ...Section F Wiring Diagrams...F-1 thru F-3 Dimension Print...F-4 Parts List ...P342 Series &...

  • Page 9: Installation

    TECHNICAL SPECIFICATIONS - PYTHON THREE PHASE Standard Input Current Voltage at Rated Output 208/230/460 48/44/25 460/575 28/20 Duty Cycle 60% Duty Cycle 100% Duty Cycle Current Range 35-85 Amps REQUIRED GAS FLOW RATE 70 PSI @ 480 SCFH ( 4.8 Bar. @ 13550 LHR) RECOMMEND INPUT WIRE AND FUSE SIZES For all plasma cutting applications Based on U.S.

  • Page 10: Safety Precautions

    Read entire Installation Section before installing the PYTHON. 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 11: Input Electrical Connections

    INPUT ELECTRICAL CONNECTIONS Before installing the machine, check that input supply voltage, phase, and frequency are the same as the machine's voltage, phase, and frequency as specified on the machine's rating plate. The PYTHON should be connected only by a qualified electrician.

  • Page 12: Frame Grounding

    FRAME GROUNDING The frame of the PYTHON must be properly ground- ed. A ground terminal marked case bottom directly behind the input power switch for this purpose. The cable that is sent attached to the machine is connected to this ground terminal. See the National Electric Code for details on proper grounding methods.

  • Page 13: Gas Input Connections

    GAS INPUT CONNECTIONS Supply the PYTHON with clean compressed air or nitrogen. • Supply pressure must be between 80 psi and 120 psi. • Pressure gage, located on the front of the machine, should be set to approximately 70 PSI for a 25 ft. torch and 75 PSI for a 50 ft. torch while gas is flowing (purging or cutting).

  • Page 14: Operation

    Read and understand this entire section before oper- ating the machine. 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.

  • Page 15: 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 flow rate and equipment may produce results different than those expected.

  • Page 16: Cutting Capability

    CUTTING CAPABILITY The PYTHON is rated at 80 amps, at 60% duty cycle on a 10 minute basis or 60 amps, at 100% duty cycle. If the duty cycle is exceeded, a thermal protector will shut off the output of the machine until it cools to the normal oper- ating temperature.

  • Page 17: Limitations

    LIMITATIONS Do not exceed the output current and duty cycle rating of machine. Do not use the PYTHON for pipe thawing. CONTROLS AND SETTINGS Reset Purge Status Button Button Indicators XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX Output Control Knob PYTHON Consumable...
  • Page 18 • Hold the nozzle standoff 1/8” (3.2mm) to 3/16” (4.7mm) above the workpiece during cutting. Do not let the nozzle touch the work or carry a long arc. • Keep moving while cutting. Cut at a steady speed without pausing. Maintain the cutting speed so that the arc leg is 10°...

  • Page 19: Pilot Arc Discussion

    PILOT ARC DISCUSSION The PYTHON 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.

  • Page 20: Suggestions For Extra Utility From The Python System

    Suggestions for Extra Utility from the PYTHON System: WARNING ELECTRIC SHOCK CAN KILL. • Turn off machine at the disconnect switch on the front of the machine before tightening, cleaning or replacing consumables. ---------------------------------------------------------------------------- 1. Occasionally an oxide layer may form over the tip of the electrode, creating an insulating barrier between the electrode and nozzle.

  • Page 21: Accessories

    ALWAYS USE GENUINE LINCOLN ELECTRIC ELECTRODES AND VORTECH™ NOZZLES • Only Genuine Lincoln Electric consumables yield the best cutting performance for the PYTHON. • The patented VORTECH™ nozzle provides an extra “kick” of swirl as the arc exits the nozzle which improves cutting performance.

  • Page 22: 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 23: Routine Maintenance

    ROUTINE MAINTENANCE 1. Keep the cutting or gouging area and the area around the machine clean and free of combustible materials. No debris should be allowed to collect which could obstruct air flow to the machine. 2. Every 6 months or so, the machine should be cleaned with a low pressure airstream.

  • Page 24: 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 25 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) 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.

  • Page 26: Wiring Diagrams

    Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) The PYTHON powers up properly but there is no response when the trigger 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 27 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 28 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 29 Observe all Safety Guidelines detailed throughout this manual SYMPTOM Machine is unresponsive immediately after power-up. The Air Low LED is lit The Safety LED is flashing The Safety LED is lit and steady The Thermal LED is lit The “Ready”, “Air Low” and “Thermal” LED’s are flashing TROUBLESHOOTING STATUS BOARD INDICATORS...
  • Page 30 xxxxxxx DIAGRAMS MACHINE FRONT ELEC MACHINE REAR PYTHON...
  • Page 31 xxxxxxx DIAGRAMS MACHINE FRONT ELEC MACHINE REAR PYTHON...
  • Page 32 xxxxxxx DIAGRAMS ELEC PYTHON...
  • Page 33 xxxxxxx DIAGRAMS ELEC PYTHON...
  • Page 34 DIAGRAMS PYTHON...
  • Page 35 ● WARNING ● Spanish ● AVISO DE PRECAUCION ● French ● ATTENTION ● ● German WARNUNG ● Portuguese ● ATENÇÃO ● Japanese Chinese Korean Arabic ● ● ● ● ● ● ● ● ● ●...
  • Page 36 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Spanish ● PRECAUCION French ● ATTENTION ● German WARNUNG Portuguese ● ● Japanese Chinese Korean Arabic WARNING AVISO DE ATENÇÃO...
  • Page 37 • 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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Red-d-arc python

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