Lincoln Electric TOMAHAWK TM 625 IM10020 Operator's Manual

Lincoln electric welder user manual

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IM10020

TOMAHAWK

625

™

January, 2011

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.

OPERATOR'S MANUAL

• 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 Electric TOMAHAWK TM 625 IM10020

Page 1 RETURN TO MAIN MENU IM10020 TOMAHAWK ™ January, 2011 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 ...
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 purchase a copy of “Safety in Welding &...
Page 3: Electric And Magnetic Fields
4.c. When not cutting or gouging, make certain no part of the elec- trode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard. 4.d. Do not cut or gouge tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside.
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 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 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
TECHNICAL SPECIFICATIONS -TOMAHAWK™ 625 INPUT - SINGLE PHASE 50 / 60 HERTZ Duty Cycle 100% Current Range 10-40 Amps REQUIRED GAS FLOW RATE 70 PSI @ 125-200 SCFH ( 5 Bar. @ 80±20 LITERS/MIN.) RECOMMEND INPUT WIRE AND FUSE SIZES Based on U.S.
Page 9: Installation
Read entire Installation Section before installing the TOMAHAWK™ 625. 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 equip- ment.
Page 10: Gas Input Connections
The following Lincoln engine drives meet these condi- tions when run in the high idle mode: Outback 189, Ranger 225, 250, 250LPG, 305G and 305D engine drives. Vantage 300, 400, 500 and Air Vantage engine drives. Some engine drives do not meet these conditions (e.g.
Page 11: Operation
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. FUMES AND GASES can be dangerous. •...
Page 12: 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 13: Cutting Capability
CUTTING CAPABILITY The TOMAHAWK™ 625 is rated at 40 amps, at 35% duty cycle on a 10 minute basis. 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 14: Limitations
LIMITATIONS Do not exceed output current and duty cycle rating of machine. Do not use the TOMAHAWK™ 625 for pipe thawing. If the arc turns off while cutting using low input volt- age, that is below 208V, lower the air pressure by adjusting the regulator knob.
Page 15: Cutting Process
5. Air Pressure Gauge and Regulator Knob: Allows regulation and monitoring of the air pressure. Items 6 thru 9 on the back of the TOMAHAWK™ 625 (See Figure B.3) 6. Fan: Provides machine cooling. When the machine is switched ON, the fan runs continuously. 7.
Page 16 • When ready to 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. (Exceptions: the first time that the trigger is pulled after the machine is turned on, or after a thermal trip out, initial trigger will be ignored.
Page 17: Pilot Arc Discussion
• Replace the nozzle when the orifice exit is eroded away or oval shaped. • After the problem is found, or if there is nothing apparently wrong, reset the machine by turning the power switch OFF and then ON again. (It is possi- ble for electrical noise to trip the safety circuit on rare occasions.
Page 18: Suggestions For Extra Utility From The Tomahawk™ 625 System
Suggestions for Extra Utility from the TOMAHAWK™ 625 System: WARNING ELECTRIC SHOCK CAN KILL. • Turn off machine at the disconnect switch on the rear 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 19: Torch Part Configuration
OPERATION TORCH PART CONFIGURATIONS w w w . l i n c o l n e l e c t r i c . c o m 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.
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: Routine Maintenance
WARNING ELECTRIC SHOCK CAN KILL. • Have an electrician install and ser- vice this equipment. • Turn the input power off at the fuse box before working on equipment. • Do not touch electrically hot parts. --------------------------------------------------------------------- ROUTINE MAINTENANCE 1. Keep the cutting or gouging area and the area around the machine clean and free of combustible materials.
Page 23: 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 24: Torch
Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Input circuit breaker trips repeatedly. 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 25 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) The TOMAHAWK™ 625 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 26 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 27 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Pilot arc starts but will not transfer when brought near work. Pilot arc initiates but turns off before transferring to work. Cutting arc appears to turn off while cutting. 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 28 Observe all Safety Guidelines detailed throughout this manual SYMPTOM When trigger is pulled Red output LED is Blinking or steady with no air flow. The Green, Red and Yellow LED’s are lit and steady. Indicates safety circuit is open. The Thermal LED is lit. When the trigger is pulled the Red and Yellow LED’s are blinking together and the Green light is on.
Page 29 DIAGRAMS ENHANCED DIAGRAM TOMAHAWK™ 625...
Page 32 • 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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Tomahawk 625