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Lincoln Electric PRO-CUT IM595-A Operator's Manual

Lincoln electric welding system user manual
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For use with machines having Code Numbers:
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.
• 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
RETURN TO MAIN MENU
PRO-CUT
10573, 10574, 10575, 10576, 10577, 10578
11019, 11020, 11021, 11022, 11023, 11024
OPERATOR'S MANUAL
• World's Leader in Welding and Cutting Products •
80
TM
Copyright © 2004 Lincoln Global Inc.
IM595-A
May, 2004

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Summary of Contents for Lincoln Electric PRO-CUT IM595-A

  • Page 1 PRO-CUT For use with machines having Code Numbers: 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...

  • 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.

  • 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 Power Input Connection for 208/230/460 Volt Machines ...A-3 Power Input Connection for 200/380-415 Volt Machines ...A-3 Input Power Cord Connector Installation...A-3 Cord Removal ...A-3 Cord Installation ...A-3...
  • 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 thru E-7 Wiring Diagrams ...Section F Wiring Diagrams...F-1 thru F-4 Dimension Print...F-5 Parts List ...P340, P210-K Series TABLE OF CONTENTS Page...

  • Page 9: Installation

    TECHNICAL SPECIFICATIONS - PRO-CUT 80 THREE PHASE Standard Input Current Voltage at Rated Output 208/230/460 48/44/25 200/380-415 46/27/24 460/575 25/20 Duty Cycle 60% Duty Cycle 100% Duty Cycle Current Range 35-85 Amps REQUIRED GAS FLOW RATE 70 PSI @ 480 SCFH ( 4.8 Bar.

  • Page 10: Safety Precautions

    Read entire Installation Section before installing the PRO-CUT 80. 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 Pro-Cut 80 should be connected only by a quali- fied electrician.

  • Page 12: Frame Grounding

    FRAME GROUNDING The frame of the Pro-Cut 80 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 PRO-CUT 80 with clean compressed air or nitrogen. • Supply pressure must be between 80 psi(5.6kg/cm and 120 psi(8.4kg/cm • Pressure gage, located on the front of the machine, should be set to approximately 70 psi(4.9kg/cm a 25ft.(7.6m) torch and 75 psi(5.3kg/cm ft.(15.2m) torch while gas is flowing (purging or cut- ting).

  • 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 PRO-CUT 80 is rated at 80 amps, at 60% duty cycle on a 10 minute basis (runs 80 amps for 6 minutes, then idling for 4 minutes) or 60 amps, at 100% duty cycle (continuous use). 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.

  • Page 17: Limitations

    LIMITATIONS Do not exceed the output current and duty cycle rating of machine. Do not use the PRO-CUT 80 for pipe thawing. CONTROLS AND SETTINGS Reset Purge Status Button Button Indicators XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX Output Control Knob PRO-CUT 80...

  • Page 18: Safety Led

    • Hold the nozzle standoff 1/8” (3.2mm) to 3/16” (4.8mm) 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 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.

  • Page 20: Suggestions For Extra Utility From The Pro-Cut System

    Suggestions for Extra Utility from the PRO-CUT 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 PRO-CUT 80. • 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 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 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: Wiring Diagrams

    Contact your local Lincoln Authorized Field Service Facility. NOTE: Make sure that consumables are Lincoln Electric brand consum- able parts. These parts are patented and using any other replacement consumables may cause damage to the torch or reduce cut quality. Also...
  • Page 31 G4239 xxxxxxx DIAGRAMS MACHINE FRONT ELEC MACHINE REAR PRO-CUT 80 G4238...
  • Page 32 xxxxxxx DIAGRAMS MACHINE FRONT ELEC MACHINE REAR PRO-CUT 55...
  • Page 33 xxxxxxx DIAGRAMS Enhanced Diagram ELEC PRO-CUT 55...
  • Page 34 xxxxxxx DIAGRAMS ELEC PRO-CUT 55...
  • Page 35 DIAGRAMS PRO-CUT 80...
  • Page 36 NOTES PRO-CUT 80...
  • Page 37 ● WARNING ● Spanish ● AVISO DE PRECAUCION ● French ● ATTENTION ● German ● WARNUNG ● Portuguese ● ATENÇÃO ● Japanese Chinese Korean Arabic ● ● ● ● ● ● ● ● ● ●...
  • Page 38 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Spanish ● PRECAUCION French ● ATTENTION German ● WARNUNG Portuguese ● ● Japanese Chinese Korean Arabic WARNING AVISO DE ATENÇÃO...
  • Page 39 • 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...

This manual is also suitable for:

Pro-cut 80

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