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Lincoln TOMAHAWK 625 Operator's Manual
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Lincoln TOMAHAWK 625 Operator's Manual

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IM10020
T T OMAHAWK
625
™
January 2013
11580
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 thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before
you act and be careful.
OPERATORʼS MANUAL
Copyright © 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 TOMAHAWK 625

  • Page 1 ™ January 2013 11580 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 thoughtful operation on your part.

  • Page 2: Electric Shock Can Kill

    SAFETY 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 recommended that you purchase a copy of “Safety in Welding &...
  • Page 3 SAFETY FOR ELECTRICALLY 4.c. When not cutting or gouging, make certain no part of the elec- trode circuit is touching the work or ground. Accidental contact powered equipment. can cause overheating and create a fire hazard. 6.a. Turn off input power using the disconnect 4.d.
  • Page 4 NOTES...
  • Page 5 SAFETY PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque dʼincendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce 7.
  • Page 6 Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses- sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor- mation or advice.

  • Page 7: Table Of Contents

    TABLE OF CONTENTS Page 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...

  • Page 8: Installation

    INSTALLATION TECHNICAL SPECIFICATIONS -TOMAHAWK™ 625 INPUT - SINGLE PHASE 50 / 60 HERTZ Standard Voltage 208V, 230V ±10% / 1 / 50 / 60Hz RATED OUTPUT AT 40° C Duty Cycle CURRENT AMPS VOLTAGE VOLTS 100% 24 A 89.6VDC 29 A 91.8VDC 40 A 96.0VDC...

  • Page 9: Safety Precautions

    INSTALLATION Read entire Installation Section before installing the HIGH FREQUENCY INTERFERENCE TOMAHAWK™ 625. PROTECTION The TOMAHAWK™ 625 employs a touch start mech- SAFETY PRECAUTIONS anism for arc initiation which eliminates high frequen- cy emissions from the machine as compared with WARNING spark gap and solid state type high frequency genera- tors.

  • Page 10: Gas Input Connections

    INSTALLATION NOTE: When using nitrogen gas from a cylinder, the The following Lincoln engine drives meet these condi- cylinder must have a pressure regulator. tions when run in the high idle mode: Outback 185, Ranger 225, 250, 250LPG, 305G and •...

  • Page 11: Operation

    OPERATION DESCRIPTION SAFETY PRECAUTIONS WARNING The TOMAHAWK™ 625 is a constant current, contin- uous control plasma cutting power source. It provides superior and reliable starting characteristics, cutting ELECTRIC SHOCK visibility and arc stability. The control system has a can kill. safety mechanism to insure that the nozzle and elec- •...

  • Page 12: User Responsibility

    OPERATION 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 13: Cutting Capability

    (Example: Electrode and Nozzle). This standoff of 0.15".) will maximize the performance of the TOMAHAWK™ 625 system. Figure B.1 Tomahawk 625 - Cut Capacity Chart 0.125 0.25 0.375 0.625 0.75...

  • Page 14: Limitations

    OPERATION LIMITATIONS LEDs Description Output Thermal (Red) (Yellow) Do not exceed output current and duty cycle rating of The cutting torch is energized. machine. Do not use the TOMAHAWK™ 625 for pipe Part in place error: the retaining thawing. cap is not properly Attached. If the arc turns off while cutting using low input volt- To restore the machine: age, that is below 208V, lower the air pressure by...

  • Page 15: Cutting Process

    OPERATION Turn the machine's ON/OFF POWER SWITCH to the 5. Air Pressure Gauge and Regulator Knob: Allows OFF position. regulation and monitoring of the air pressure. • Connect the air supply to the machine. Items 6 thru 9 on the back of the TOMAHAWK™ 625 (See Figure B.3) •...
  • Page 16 OPERATION • When ready to cut, place the torch near the work, 5 - 15 Leading Angle 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.

  • Page 17: Pilot Arc Discussion

    OPERATION • Replace the nozzle when the orifice exit is eroded PROCEDURE RECOMMENDATIONS away or oval shaped. When properly used, plasma arc cutting is a very eco- • After the problem is found, or if there is nothing nomical process. Improper use will result in a very apparently wrong, reset the machine by turning the high operating cost.

  • Page 18: Suggestions For Extra Utility From The Tomahawk™ 625 System

    ELECTRIC SHOCK CAN KILL. • Turn off machine at the disconnect • Use only Lincoln consumable parts. These switch on the rear of the machine parts are patented and using any other replace- before tightening, cleaning or replacing ment consumables may cause damage to the consumables.

  • Page 19: Torch Part Configuration

    OPERATION TORCH PART CONFIGURATIONS There are different torch configurations depending on the cutting or gouging application. Standard Cutting Setup: In the Standard Cutting configuration the nozzle is designed not to touch the work piece. The advantage of this cutting method is good visibility of the arc. However it requires a steady hand to avoid touching the nozzle to the work piece which will cause prema- ture nozzle wear and a jagged cut.
  • Page 20 Refer to the torch parts decal located on your machine or the parts pages at the back of this manual for the specific part numbers required for each of these setups. ALWAYS USE GENUINE LINCOLN ELECTRIC ELECTRODES, NOZZLES, AND EXPENDABLE PARTS FOR THE BEST CUTTING PERFOR- MANCE.

  • Page 21: Accessories

    ACCESSORIES GENERAL OPTIONS /ACCESSORIES The following options/accessories are available for your Tomahawk Plasma cutter from your local Lincoln Distributor. K2377-1 - Small Canvas Cover Protect your machine when not in use. Made from attractive red canvas that is flame retardant, mildew resistant and water repellent.

  • Page 22: Maintenance

    MAINTENANCE PERIODIC MAINTENANCE WARNING WARNING ELECTRIC SHOCK CAN KILL. • Have an electrician install and ser- ELECTRIC SHOCK CAN KILL. vice this equipment. • Turn off machine at the disconnect • Turn the input power off at the fuse switch on the rear of the machine box before working on equipment.

  • Page 23: Troubleshooting

    HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 24 TROUBLESHOOTING TOMAHAWK™ 625...

  • Page 25: Torch

    3. Possible faulty Control Board. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. TOMAHAWK™ 625...
  • Page 26 Field Service Facility. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. TOMAHAWK™ 625...
  • Page 27 3. Make sure the air pressure is set correctly. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. TOMAHAWK™ 625...
  • Page 28 2. Air pressure is set too high. cator. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. TOMAHAWK™ 625...
  • Page 29 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual STATUS BOARD INDICATORS SYMPTOM CHECK When trigger is pulled Red output LED is 1. Make sure there is at least 80 psi connected to the gas connec- Blinking or steady with no air flow. tion at the back of the machine.
  • Page 30 DIAGRAMS ENHANCED DIAGRAM TOMAHAWK™ 625...
  • Page 31 NOTES TOMAHAWK™ 625...
  • Page 32 Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. • • • WARNING electrode with skin or wet clothing. Insulate yourself from work and • ground. Spanish No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el •...
  • Page 33 Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or • • • WARNING Use ventilation or exhaust to guards off. • remove fumes from breathing zone. Spanish Los humos fuera de la zona de res- •...
  • Page 34 • 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...