Lincoln Electric PRO-CUT 125 IM491-B Operator's Manual
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Lincoln Electric PRO-CUT 125 IM491-B Operator's Manual

Plasma cutting power source
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PLASMA CUTTING POWER SOURCE
For use with machines having Code Numbers 10384 thru 10388
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
PRO-CUT 1 25
RETURN TO MAIN MENU
R
OPERATOR'S MANUAL
• World's Leader in Welding and Cutting Products •
®
IM491-B
October,1999

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Summary of Contents for Lincoln Electric PRO-CUT 125 IM491-B

  • Page 1 PRO-CUT 1 25 PLASMA CUTTING POWER SOURCE For use with machines having Code Numbers 10384 thru 10388 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 ...

  • Page 2: Safety Precautions

    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 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 5: Table Of Contents

    Safety Precautions ...2-4 Introductory Information ...6 Specifications...7 Product Description...8 Preheat Temperature for Plasma Cutting ...8 User Responsibility ...8 Installation ...9-11 Safety Precautions ...9 Location ...9 High Frequency Interference Protection...9 Electrical Input Connection...10 Air Input Connections ...11 Output Connections...11 Torch Connection...11 Work Cable and Clamp Installation...11 Operating Instructions ...11-14 Sequence of events...11...

  • Page 6: Introductory Information

    This statement appears where the information this equipment. for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you!

  • Page 7: Specifications

    Type K1394-* and K1395-* K880-1[25Ft.(7.6m)Cable] & K880-2 [50Ft.(15.2m)Cable] Magnum PCT125 Air Cooled Torch Input Frequency 50 or 60 Hz, 3ø Output Rating 125 Amps, 148 volts, 60% Duty Cycle 110 Amps, 140 volts, 80% Duty Cycle 100 Amps, 135 volts, 100% Duty Cycle Pilot Current 26 amps Pilot Duty Cycle...

  • Page 8: Product Description

    PRODUCT DESCRIPTION The PRO-CUT™ 125 is a constant current, single range, continuous control plasma cutting system. The system is one of the most sophisticated on the market. It provides excellent starting characteristics, cutting visibility and arc stability. The torch has a patented safety mechanism which insures that the consumables are in place before cutting or gouging.

  • Page 9: Installation

    INSTALLATION SAFETY PRECAUTIONS ● Read the safety precautions at the beginning of this Operator's Manual before proceeding. ● Only personnel that have read and under- stood this Operating Manual should install and operate this equipment. ● Machine must be connected to system ground per any national, local or other applicable electrical codes.

  • Page 10: Electrical Input Connection

    ELECTRICAL INPUT CONNECTION WARNING ELECTRIC SHOCK can kill. • Disconnect input power before proceeding. • Have a qualified electrician make the input connections. • Be sure the voltage, phase and frequency of the input power is as specified on the machine nameplate.

  • Page 11: Air Input Connections

    AIR INPUT CONNECTIONS WARNING CYLINDER may explode if damaged • Keep cylinder upright and chained to a fixed support. • Keep cylinder away from areas where it may be damaged. • Never lift equipment with cylinder attached. • Never allow the cutting torch to touch cylinder. •...

  • Page 12: Pilot Arc Discussion

    F. When ready to cut, place the work lead on the piece to be cut, place the torch near the work, 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 13: Expanded Metal

    Expanded Metal: Output set near mid-range. • Cut it as you would light gauge sheet metal. • Expanded metal is pilot arc intensive. After about 30 seconds of cutting, the pilot arc will change from a bright continuous arc to a discon- tinuous one which will sputter slightly.

  • Page 14: In All Cases

    In All Cases: • Do not pause when cutting or gouging the metal. This is not necessary and causes opera- tional difficulty. Pausing at the edge of the work- piece causes poor consumable life and erratic operation. • Always position the torch in the best way to keep dross and hot air from burning back into it.

  • Page 15: Maintenance Procedures

    MAINTENANCE PROCEDURES WARNING ELECTRIC SHOCK CAN KILL. BEFORE PERFORMING ANY MAINTE- NANCE THAT REQUIRES OPENING THE CASE OF THE POWER SOURCE: • Disconnect input power to this machine at the Disconnect switch. • Do not touch electrically live parts or internal wiring. •...
  • Page 16 SYMPTOM No LED’s light when the power switch is turned on. The “MACHINE ON” LED is lit, but there is no response when the trigger is pulled. CHECK Check the input power to be sure it is on. Check the power line fuses and machine connection.
  • Page 17 SYMPTOM The air begins to flow, the “OUTPUT ON” LED lights for a brief period, but no arc is established. The arc starts but sputters badly. The “THERMAL” LED is lit. The “MALFUNCTION” LED is blinking. The “MALFUNCTION” LED is blinking two short flashes in close succession followed by a one second off period.
  • Page 18 SYMPTOM The “MALFUNCTION” LED is lit. Alternating “AIR/MALFUNCTION” LED lights Air pressure cannot be set to 60 psi (414 kPa) or the machine cuts poorly through thick sections. CHECK The FAULT circuit monitors the torch to see if it is shorted as well as internal machine failures.
  • Page 19 SYMPTOM The “SAFETY” LED is lit. The “OUTPUT ON” and “MALFUNCTION” LED’s blink in alternating order. Airflow will not shut off. No OCV when 2 and 4 are closed. CHECK The machine will not operate. The machine senses that the shield cup is not in place, or the operators could be exposed to dangerous voltages if the machine were allowed to operate.

  • Page 20: Pro-Cut 125 Status Lights Operating Modes

    PRO-CUT 125 STATUS LIGHTS OPERATING MODES STATUS LIGHTS MACHINE ON Should always be on when machine is on. Normal OUTPUT ON On when there is voltage potential at the torch (cutting or pilot). OUTPUT ON is blinking alternately with AIR PRESSURE when power is first applied to machine.
  • Page 21 STATUS LIGHTS SAFETY It is possible that this light could turn on when power is first applied to machine. The torch assembly is misconnected or damaged. The shield cup assembly is not in place. While cutting or gouging if the voltage between the nozzle and the work is too high, it will put the machine into safety.

  • Page 22: Procedure For Replacing Pc Boards

    PROCEDURE FOR REPLACING PC BOARDS WARNING ELECTRIC SHOCK CAN KILL. BEFORE PERFORMING ANY MAINTE- NANCE THAT REQUIRES OPENING THE CASE OF THE POWER SOURCE: • Disconnect input power to this machine at the Disconnect switch. • Do not touch electrically live parts or internal wiring. •...
  • Page 23 NOTES – 23 –...

  • Page 24: Parts Lists

    PCT 125 AMP PLASMA TORCH Parts List P-210-C 2-10-92 – 24 –...
  • Page 25 PCT 125 AMP PLASMA TORCH Item Description Mag PCT-125 Torch & Cable (25’) Mag PCT-125 Torch & Cable (50’) Cable Asbly (25’) Cable Asbly (50’) Handle Repair Kit Handle (LH), Includes: Handle Nut Handle (RH), Includes: Pan Handle Screw (#6-32 x .75) Torch Head O-Ring, Shield Cup O-Ring, Handle...
  • Page 26 GENERAL ASSEMBLY Parts List P-207-C PRO-CUT 125 THREE PHASE Drop in photos from P-207-C parts page. – 26 –...
  • Page 27 GENERAL ASSEMBLY PRO-CUT 125 THREE PHASE Part Item Description Base L8473 Base Support L8472 Foot L8284 Thread Forming Screw S9225-26 Caster S11124-8 Thread Forming Screw S9225-28 Axle T6988-22 Wheel S17073-4 Plain Washer S9262-142 Cotter Pin S10750-1 Case Front Asbly See P-184-D Self Tapping Screw S8025-65 Left Case Side (Not Shown)

  • Page 28: Case Back Assembly

    Parts List P-207-D Item CASE BACK ASSEMBLY Part Description Case Back L7753-1 Fan & Baffle Asbly, Includes: M15585 Fan Baffle L7666 Fan Blade M8678-2 Fan Motor M8895-5 Fan Mounting M14064 Self Tapping Screw S8025-70 Self Tapping Screw S8025-65 Grommet S10255-12 Rear Nameplate S19840 Fastener Button...

  • Page 29: Solenoid Assembly

    SOLENOID ASSEMBLY Item Hose Nipple (Male) Solenoid Pipe Tee Pressure Switch PC Board Plug Hex Nipple Male Run Tee Solenoid Part Description T14557-11 S18127-4 T10366 S18638-1 S14156-1 T11289-3 S19932-1 S18127-5 – 29 – Parts List P-207-E S18667-5 Req’d. 10-27-93...
  • Page 30 REGULATOR AND FILTER ASSEMBLY Parts List P-184-E Item 9-6-93 Part Description Filter/Regulator Asbly M16480 Filter Element (.50 ID x 1.14” Long) M16480-B Panel Mounting Nut M16480-C Oil/Coalescing Filter S19865 Filter Element (.45 ID x 1.16” Long) S18637-2 Filter Element (.56 ID x 1.42” Long) S19865-A Hex Nipple T11289-1...
  • Page 31 INPUT BOX ASSEMBLY R E A R V I E W F R O N T V I E W A C 1 A C 2 A C 3 C R 1 Item Description Input Box Heat Sink Thread Forming Screw Reconnect Panel Asbly Insulation Plastic Expansion Nut...
  • Page 32 Parts List P-207-G Item HI FREQ BOARD ASSEMBLY Part Description Mounting Board Asbly S19700 Carriage Bolt T11827-23 Hex Nut 1/4-20 Brass Hex Nut 1/4-20 Sems Screw T10082-8 Hex Nut (Brass) #10-24 Wing Nut T9968-4 Carriage Bolt T11827-23 Hex Nut 1/4-20 Coiler Asbly, Includes: S19689 Hi-Freq Choke Coil...

  • Page 33: Parts Lists

    CASE FRONT ASSEMBLY Part Item Description Case Front G1873-1 Nameplate (Domestic) L8315 Nameplate (Export) L8354 PC Board Asbly M16301-1 Self Tapping Screw S8025-71 Reset Button (S2) T15089 Run/Purge Switch (S2) T10800-13 Potentiometer (R1) T10812-40 Spacer S18280 Knob T10491 Line Switch Assembly (Dual & Triple Voltage) M16284 Line Switch Assembly (Single Voltage) M16284-1...

  • Page 34: Input Supply Connection For Triple Voltage Machine

    2. CONNECT TERMINAL MARKED TO GROUND PER NATIONAL ELECTRICAL CODE. 3. REMOVE HEX NUTS AND POSITION LINKS AS SHOWN. REPLACE AND TIGHTEN ALL HEX NUTS. THE LINCOLN ELECTRIC CO., CLEVELAND, OHIO U.S.A. FIGURE 1- DUAL & TRIPLE VOLTAGE GND. LINK 575 V.,60HZ.

  • Page 35: Cutting Torch Connection Diagram

    PLASMA TORCH CONNECTION DIAGRAM FOR LINCOLN ELECTRIC TORCHES M O L E X C O N N E C T O R S C O R D G R I P C O N N E C T O R 1 .

  • Page 36: Wiring Diagram Pro-Cut 125

    – 36 –...
  • Page 37 _______________________________________________ _______________________________________________ Telephone: _______________________________________________ |_|_| |_|_| Exp Date Month Year BOOK DIVISION, The Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199 for fastest service, FAX this completed form to: 216-361-5901 Telephone: 216-383-2211 or, Price Code $5.00 $15.00 $4.50 $5.00...
  • Page 38 Do not touch electrically live parts or ● WARNING electrode with skin or wet clothing. ● Insulate yourself from work and ground. Spanish ● No toque las partes o los electrodos AVISO DE bajo carga con la piel o ropa moja- PRECAUCION Aislese del trabajo y de la tierra.
  • Page 39 Keep your head out of fumes. Turn power off before servicing. ● ● ● Use ventilation or exhaust to remove fumes from breathing zone. Los humos fuera de la zona de res- ● ● Desconectar el cable de ali- piración. mentación de poder de la máquina ●...
  • Page 40 • 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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