Lincoln Electric TOMAHAWK 1025 Service Manual
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Lincoln Electric TOMAHAWK 1025 Service Manual

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SVM 2014
Rev.02 12-2017
TOMAHAWK
1025 & 1538
®
For use with machines having code numbers: 52076, 52095
LINCOLN ELECTRIC EUROPE
www.lincolnelectric.eu

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  • Page 1 SVM 2014 Rev.02 12-2017 TOMAHAWK 1025 & 1538 ® For use with machines having code numbers: 52076, 52095 LINCOLN ELECTRIC EUROPE www.lincolnelectric.eu...

  • Page 2: Table Of Contents

    INDEX OF CONTENTS INDEX OF CONTENTS ............................. 2 TECHNICAL SPECIFICATIONS ..........................3 SAFETY ..................................4 INSTALLATION AND OPERATOR INSTRUCTIONS ....................5 MAINTENANCE ..............................10 MAJOR COMPONENTS LOCATION ........................11 THEORY OF OPERATION ............................. 13 INPUT SECTION ..............................14 INVERTER SECTION AND MAIN TRANSFORMER ..................... 15 OUTPUT SECTION AND TORCH ..........................

  • Page 3: Technical Specifications

    TECHNICAL SPECIFICATIONS Page 3...

  • Page 4: Safety

    Read and understand the following explanations of the warning symbols. Lincoln Electric is not responsible for damages caused by improper installation, improper care or abnormal operation.

  • Page 5: Installation And Operator Instructions

    Electric shock from torch or wiring can kill. Wear dry insulating gloves. Do not wear wet or damaged gloves. Protect yourself from electric shock by insulating yourself from work and ground. Disconnect input plug or power before working on machine. Breathing cutting fumes can be hazardous to your health.
  • Page 6 If one or some LED remains OFF, contact the • After the torch is restored, the nearest technical service center or Lincoln Electric and report machine cannot restart for about 5 the LED Status found on the machine Front Panel.
  • Page 7 ON again. If the error remains, a maintenance is required. Please contact the nearest Rear Panel Controls and Connections technical service center or Lincoln Electric and report the A. Fan: This machine has a LED Status found on the machine Front Panel.
  • Page 8 WARNING Maintenance A clean, dry primary gas (air or nitrogen) must be supplied to the machine. A pressure setting above WARNING 7,5bar could damage the torch. Failure to observe For any maintenance or repair operations it is recommended these precautions could result in excessive operating to contact the nearest technical service center or Lincoln temperatures or damage to the torch.
  • Page 9 Lincoln Electric. Before installing the machine, the operator must check the work area for any devices that may malfunction because of electromagnetic disturbances.

  • Page 10: Maintenance

    MAINTENANCE WARNING INPUT FILTER CAPACITOR DISCHARGE PROCEDURE Remove input power to Tomahawk machine ELECTRIC SHOCK can kill Remove the cover following the instruction available in this Service manual. Have an electrician install and service this equipment Obtain a high resistance and high wattage resistor ( 25- Turn the input power off at the fuse box before working on 1000 ohms and 25 watts minimum ).

  • Page 11: Major Components Location

    15 minute period. If the fan is not turning or the air intake louvers were obstructed , then the power must be switched off and the fan problem or air obstruction must be corrected. MAJOR COMPONENTS LOCATION TOMAHAWK 1025 Page 11...
  • Page 12 TOMAHAWK 1538 Page 12...

  • Page 13: Theory Of Operation

    THEORY OF OPERATION  General description  Input Line Voltage, Auxiliary Voltage, Precharge  Inverter Board , Main Transformer, Output Rectifier and Choke  Control Board  Air System  Protection Circuits  IGBT operation BLOCK DIAGRAM Page 13...

  • Page 14: Input Section

    INPUT SECTION  the auxiliary power supplies (+24, +15V, -5V) GENERAL DESCRIPTION to all the boards will be generated.  a uController on the input board manages the The Tomahakw 1025 and 1538 are inverter based soft stat and pre-charge operation. If the plasma cutting power sources that offers standard cut, uController is correctly programmed LED LD1 grid cut and gouging.

  • Page 15: Inverter Section And Main Transformer

    INVERTER SECTION AND MAIN TRANSFORMER Inverter and Main Transformer When the input filter capacitors are fully charged they inverter heatsink, to protect the IGBTs from act as power supplies for the IGBT switching circuit. overheating conditions. The IGBT switch the DC power from the input capacitors "on and off,"...

  • Page 16: Output Section And Torch

    OUTPUT SECTION AND TORCH Output section and Torch The output section contains a static switch, upon the nozzle. Plasma arc initiation occurs as follows: receiving a pilot signal from the control board will first, in the idle state, a spring inside the torch head enable the operation of a pilot arc or a cutting arc.

  • Page 17: Control Board

    CONTROL BOARD Control Board (User Interface) The control board receives status and analog feedback signals from the inverter board, input board and various sensors. The control circuitry interprets these signals, makes decisions and changes the machines mode and output to satisfy the requirements as defined by the circuitry or user.

  • Page 18: Air System

    AIR SYSTEM The air system is integrated inside the machine. Air system circuit is composed by the following major components:  Air Filter: it has two functions, it filters the small pollution (5um) that goes to the torch and it eliminates the 90% of the moisture contained in the air that supplies the torch.
  • Page 19 Excessive temperature may be caused by a lack of The Tomahawk 1025 and 1538 have a protection cooling air or by operating the machine beyond the circuit (PIP) to detect the proper installation of the duty cycle and output rating.
  • Page 20 INSULATED GATE BIPOLAR TRANSISTOR (IGBT) Drawing B shows the IGBT in an active mode. OPERATION When the gate signal, a positive DC voltage relative to the source, is applied to the gate An IGBT is a type of transistor. IGBTs are terminal of the IGBT, it is capable of conducting semicon-ductors well suited for high frequency current.

  • Page 21: Troubleshooting And Repair Section

    TROUBLESHOOTING AND REPAIR SECTION  How to use troubleshooting Guide  Troubleshooting Guide  Case cover removal and capacitor discharge procedure  Input board resistance test  Inverter board resistance test  Output board resistance test  Input board voltage test ...

  • Page 22: How To Use Troubleshooting Guide

    HOW TO USE TROUBLESHOOTING GUIDE Service and repair should be performed by only 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 23 WARNING NOTE: Allow the machine to heat up so that all electrical components can reach their operating temperature. 5. Remove the replacement PC board and ELECTRIC SHOCK can kill substitute it with the original PC board to recreate the original problem. ...
  • Page 24 TROUBLESHOOTING !! WARNING !! BEFORE CONNECT POWER SUPPLY, MAKE A CAREFUL VISUAL INSPECTION INSIDE THE MACHINE , CHECK ALL THE BOARDS AND HARNESS. PROBLEMS / SYMPTOMS CHECKS RECOMMENDED COURSE OF ACTION  CHANGE THE PART BROKEN AND A VISUAL DAMAGE IS EVIDENT ------------------------------------------- PERFORM THE TESTS FOR THE WHEN YOU OPEN THE COVER...

  • Page 25: Case Cover Removal And Dc Link Capacitor Discharge Procedure

    DISCHARGE PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result in danger to the technician or 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 26 TOMAHAWK 1025 - CASE COVER REMOVAL Procedure: 1. Disconnect Input Power from the machine! 2. Turn on/off switch to off position. 3. Remove the 2 screws of the alluminum handle (A). 4. Remove the 16 screws of the plastic handle (B).
  • Page 27 TOMAHAWK 1538 - CASE COVER REMOVAL Procedure: 1. Disconnect Input Power from the machine! 2. Turn on/off switch to off position. 3. Remove the 16 screws of the plastic handle (B). 4. Remove the 4 screws on the rubber corners (C). 5.
  • Page 28 DC LINK CAPACITORS DISCHARGE PROCEDURE INPUT FILTER CAPACITOR WARNING DISCHARGE PROCEDURE 1. Remove input power to Tomahawk machine 2. Remove the cover following the instruction available in this Service manual. ELECTRIC SHOCK can kill 3. Obtain a high resistance and high wattage resistor ( 25-1000 ohms and 25 watts Have an electrician install and service this equipment minimum ).

  • Page 29: Input Board Resistance Test

    INPUT BOARD RESISTANCE TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 30 INPUT BOARD RESISTANCE TEST (continued) Picture is related to TOMAHAWK 1025 Input board . TOMAHAWK 1538 input board is the same only without the four black snap-in capacitors AC input power supply 400V +/- 15% PTC1 test points (left resistence leg...

  • Page 31: Inverter Board Resistance Test

    INVERTER BOARD RESISTANCE TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 32 W05X0857-1 on TH1025 W05X0857-2 on TH1538 TEST PROCEDURE 1. Remove main input power to the TOMAHAWK 1025 or 1538 2. Perform the Discharge procedure 3. Visually check for burned or damaged components. If any components are physically damaged the inverter board should be replaced 4.

  • Page 33: Output Board Resistance Test

    OUTPUT BOARD RESISTANCE TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 34 1538 ! W05X0858-2 on TH1538 TEST PROCEDURE 1. Remove main input power to the TOMAHAWK 1025 or 1538 2. Perform the Discharge procedure 3. Visually check for burned or damaged components. If any components are physically damaged the output board should be replaced 4.

  • Page 35: Input Board Voltage Test

    INPUT BOARD VOLTAGE TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 36 INPUT BOARD VOLTAGE TEST (continued) DC BUS - 400VAC +/- 15% DC BUS + 3 Phase INPUT to inverter bd to remote to fan bd (optional) Use this heatsink as to control bd SGND reference for voltage tests W05X0855-1 on TH1025 W05X0855-2 on TH1538 to output bd to solenoid valve...
  • Page 37 INPUT BOARD VOLTAGE TEST (continued) J4: Fan connector Pin# Description Value Notes 15 Vac in idle mode Fan is switch ON by signal 230Vac when fan ON coming from control board J2: Input/Control connector Pin# Description Value (use SGND as 0V ref.) Notes +15V +15Vdc...
  • Page 38 INPUT BOARD VOLTAGE TEST (continued) J5: Gas/Air Solenoid Valve connector Pin# Description Value (use SGND as 0V ref.) Notes +15V +15Vdc +15V power supply generated by the input board.  0V=normal value GASERR Air pressure signal  12,5Vdc= gas/air error +24V +24Vdc Not used...

  • Page 39: Inverter Board Voltage Test

    INVERTER BOARD VOLTAGE TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 40 INVERTER BOARD VOLTAGE TEST (continued) BLUE= V at 60A/105V output RED = V 60A/105V output GE at to input bd W05X0857-1 on TH1025 W05X0857-2 on TH1538 TEST PROCEDURE 1. Apply 400V +/- 15% to the TH1025 or 1538 2. Turn the machine input swith to ON position, and wait till the power LED on front panel is stady green. 3.

  • Page 41: Output Board Voltage Test

    OUTPUT BOARD VOLTAGE TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 42 OUTPUT BOARD VOLTAGE TEST (continued) HCS1Current Workpiece Hall Sensor Transducer to input bd Static Switch (IGBT) PIP&Trigger HCS2 Current Electrode Hall Sensor Transducer Not used for CE versions W05X0858-1 on TH1025 W05X0858-2 on TH1538 TEST PROCEDURE 1. Apply 400V +/- 15% to the TH1025 or 1538 2.

  • Page 43: Control Board Test

    CONTROL BOARD TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 44 CONTROL BOARD TEST (continued) Cutting modes LEDs Production testing connector – Internal use only Operative LEDs Cutting mode selection To Input bd programming – internal use only uController Output current potentiometer TEST PROCEDURE 1. Apply 400V +/- 15% to the TH1025 or 1538 2.

  • Page 45: Error Codes

    ERROR CODES OUTPUT POWER ON THERMAL ERROR GAS ERROR P.I.P. ERROR ENERGIZED ERROR Input voltage out BLINKING of range Head Torch (1) BLINKING N.I. N.I. BLINKING No pilot arc Trigger pushed Internal voltage BLINKING lockout (2) Thermal alarm Gas alarm Part in Place alarm (1) Error appears if after 4 seconds of pilot arc the cutting process has not started...
  • Page 46 ERROR CODES (continued) Low gas pressure condition LED: With this LED ON the machine stops cutting or gouging operations. The The Torch Trigger pushbutton is pressed. machine restart automatically when a During this period the machine try to start correct gas pressure is detected. the pilot arc for 4 times.

  • Page 47: Disassembly Operations

    DISASSEMBLY OPERATIONS INPUT BOARD REMOVAL AND REPLACEMENT PROCEDURE WARNING Disconnect input power before servicing. Do not operate with covers removed. Do not touch electrically live parts. Only qualified persons should install, use ELECTRIC SHOCK or service this equipment. CAN KILL Ground lead REMOVAL PROCEDURE...
  • Page 48 DISASSEMBLY OPERATIONS INVERTER BOARD REMOVAL AND REPLACEMENT PROCEDURE WARNING Disconnect input power before servicing. Do not operate with covers removed. Do not touch electrically live parts. Only qualified persons should install, use ELECTRIC SHOCK or service this equipment. CAN KILL REMOVAL PROCEDURE Necessary tools: - Phillips screwdriver PH02...
  • Page 49 DISASSEMBLY OPERATIONS INVERTER BOARD IGBT REMOVAL AND REPLACEMENT PROCEDURE WARNING Disconnect input power before servicing. Do not operate with covers removed. Do not touch electrically live parts. Only qualified persons should install, use ELECTRIC SHOCK or service this equipment. CAN KILL REMOVAL PROCEDURE Necessary tools: - Phillips screwdriver PH02...
  • Page 50 DISASSEMBLY OPERATIONS OUTPUT BOARD REMOVAL AND REPLACEMENT PROCEDURE WARNING Disconnect input power before servicing. Do not operate with covers removed. Do not touch electrically live parts. Only qualified persons should install, use ELECTRIC SHOCK or service this equipment. CAN KILL REMOVAL PROCEDURE Necessary tools: - Phillips screwdriver PH02...
  • Page 51 DISASSEMBLY OPERATIONS OUTPUT BOARD DIODE AND IGBT MODULES REMOVAL AND REPLACEMENT PROCEDURE WARNING Disconnect input power before servicing. Do not operate with covers removed. Do not touch electrically live parts. Only qualified persons should install, use ELECTRIC SHOCK or service this equipment. CAN KILL REMOVAL PROCEDURE Necessary tools:...
  • Page 52 DISASSEMBLY OPERATIONS CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE WARNING Disconnect input power before servicing. Do not operate with covers removed. Do not touch electrically live parts. Only qualified persons should install, use ELECTRIC SHOCK or service this equipment. CAN KILL REMOVAL PROCEDURE Necessary tools: - Phillips screwdriver PH02...
  • Page 53 DISASSEMBLY OPERATIONS AIR SYSTEM REMOVAL AND REPLACEMENT PROCEDURE AIR FILTER DISASSEMBLY PROCEDURE WARNING Disconnect input power before servicing. Do not operate with covers removed. Do not touch electrically live parts. Only qualified persons should install, use ELECTRIC SHOCK or service this equipment. CAN KILL REMOVAL PROCEDURE Necessary tools:...
  • Page 54 DISASSEMBLY OPERATIONS AIR SYSTEM REMOVAL AND REPLACEMENT PROCEDURE PRESSURE SWITCH DISASSEMBLY PROCEDURE WARNING Disconnect input power before servicing. Do not operate with covers removed. Do not touch electrically live parts. Only qualified persons should install, use ELECTRIC SHOCK or service this equipment. CAN KILL REMOVAL PROCEDURE Necessary tools:...
  • Page 55 DISASSEMBLY OPERATIONS AIR SYSTEM REMOVAL AND REPLACEMENT PROCEDURE GAS SOLENOID DISASSEMBLY PROCEDURE WARNING Disconnect input power before servicing. Do not operate with covers removed. Do not touch electrically live parts. Only qualified persons should install, use ELECTRIC SHOCK or service this equipment. CAN KILL REMOVAL PROCEDURE Necessary tools:...
  • Page 56 DISASSEMBLY OPERATIONS AIR SYSTEM REMOVAL AND REPLACEMENT PROCEDURE TORCH CONNECTOR DISASSEMBLY PROCEDURE WARNING Disconnect input power before servicing. Do not operate with covers removed. Do not touch electrically live parts. Only qualified persons should install, use ELECTRIC SHOCK or service this equipment. CAN KILL Necessary tools: - Phillips screwdriver PH02...

  • Page 57: Retest After Repair

    Should a machine under test be rejected for any reason requiring the removal of any mechanical part that could affect the machine’s electrical characteristics, or if any electrical components are repaired or replaced, the machine must be retested. Machine input and output Tomahawk 1025 Input Voltage Input Current Rated Output...

  • Page 58: Electrical Diagrams

    ELECTRICAL DIAGRAMS TH1025 Code 52095 Page 58...
  • Page 59 ELECTRICAL DIAGRAMS TH1538 Code 52076 Page 59...
  • Page 60 ELECTRICAL DIAGRAMS INPUT BOARD SCHEMATIC X0855 Page 60...
  • Page 61 ELECTRICAL DIAGRAMS INVERTER BOARD SCHEMATIC X0857 – IGBT DRIVER SECTION Page 61...
  • Page 62 ELECTRICAL DIAGRAMS INVERTER BOARD SCHEMATIC X0857 – IGBT SECTION Page 62...
  • Page 63 ELECTRICAL DIAGRAMS INVERTER BOARD SCHEMATIC X0857 – CONTROL CIRCUIT SECTION Page 63...
  • Page 64 ELECTRICAL DIAGRAMS OUTPUT BOARD SCHEMATIC X0858 – STATIC SWITCH AND CURRENT SENSOR Page 64...
  • Page 65 ELECTRICAL DIAGRAMS OUTPUT BOARD SCHEMATIC X0858 – DC/DC CONVERTER, TRIGGER, PIP Page 65...
  • Page 66 ELECTRICAL DIAGRAMS CONTROL BOARD SCHEMATIC X0859 Page 66...
  • Page 67 ELECTRICAL DIAGRAMS CONTROL BOARD SCHEMATIC X0859 (CONTINUED) Page 67...
  • Page 68 ELECTRICAL DIAGRAMS TORCH CONNECTION DIAGRAM TORCH CONNECTOR - POLARIZATION KEY FOR TOMAHAWK 1025 TORCH CONNECTOR - POLARIZATION KEY FOR TOMAHAWK 1538 Page 68...

  • Page 69: Plasma Torches - Lc65, Lc65M, Lc105 & Lc105M

    PLASMA TORCHES – LC65, LC65M, LC105 & LC105M LC65 Torch (Hand 7.5m) Cooling Kit PTH-061A-CX-7M5A W03X0893-49R (1pc) (blister 1pc) Torch (Hand 15m) Cable (7.5m) PTH-061A-CX-15MA W0300604R (1pc) (1pc) Handle Cable (15m) W0300609R W0300606R (1pc) (1pc) Head Connector W0300608R W03X0934-4R (1pc) (1pc) Electrode Gas Distr.
  • Page 70 LC65M Torch (Machine 7.5m) Head PTM-061A-CX-7M5A W0300610R (1pc) (1pc) Torch (Machine 15m) Cooling Kit PTM-061A-CX-15MA W03X0893-49R (1pc) (blister 1pc) Positioning tube Cable (7.5m) W0300603R W0300605R (1pc) (1pc) Positioning tube (Gear Rack) Cable (15m) W0300624R W0300607R (1pc) (1pc) Head Connector W0300610R W03X0934-4R (1pc) (1pc)
  • Page 71 LC105 Torch (Hand 7.5m) Insulation Kit PTH-101A-CX-7M5A W03X0893-71R (1pc) (blister 1pc) Torch (Hand 15m) Cable (7.5m) PTH-101A-CX-15MA W0300620R (1pc) (1pc) Handle Cable (15m) W0300609R W0300622R (1pc) (1pc) Head Connector W0300618R W03X0934-8R (1pc) (1pc) Electrode Gas Distr. (blister 5pcs) (blister 2pcs) (blister 5pcs) Cutting process W03X0893-60A...
  • Page 72 LC105M, LC105M GEAR RACK Torch (Machine 7.5m) Head PTM-101A-CX-7M5A W0300619R (1pc) (1pc) Torch (Machine 15m) Insulation Kit PTM-101A-CX-15MA W03X0893-71R (1pc) (blister 1pc) Positioning tube (Machine) Cable (7.5m) W0300603R W0300621R (1pc) (1pc) Positioning tube (Gear Rack) Cable (15m) W0300624R W0300623R (1pc) (1pc) Connector W03X0934-8R...
  • Page 73 TORCHES DIMENSIONS Page 73...

  • Page 74: Note

    NOTE Page 74...

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Tomahawk 1538

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