PRO-CUT ®60 IM399-D
(Single Phase)
May, 1999
PLASMA CUTTING SYSTEM
For use with all code number machines thru 10394
RETURN TO MAIN INDEX
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.
R
OPERATOR’S MANUAL
World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors
� 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
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 pur-
chase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1� from the American Welding Society, P.O. Box 351040,
Miami, Florida 33135 or CSA Standard W117.2.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
ELECTRIC SHOCK can FUMES AND GASES
kill. can be dangerous.
1.a. The electrode and work (or ground) circuits 3.a. Plasma cutting or gouging may produce
are electrically “hot� when the power source fumes and gases hazardous to health.
is on. Do not touch these “hot� parts with Avoid breathing these fumes and
your bare skin or wet clothing. Wear dry, gases.When cutting or gouging, keep your
hole-free gloves to insulate hands. head out of the fumes. Use enough ventila-
tion and/or exhaust at the arc to keep fumes and gases
away from the breathing zone. When cutting or gouging
1.b. When the power source is operating voltages in excess of
on lead or cadmium plated steel and other metals or
250 volts are produced. This creates the potential for serious
coatings which produce highly toxic fumes keep expo-
electrical shock - potentially even fatal.
sure as low as possible and below Threshold Limit
Values (TLV) using local exhaust or mechanical ventila-
1.c. Insulate yourself from work and ground using dry insulation.
tion. In confined spaces or in some circumstances, out-
When cutting or gouging in damp locations, on metal frame-
doors, a respirator may be required. Additional precau-
work such as floors, gratings or scaffolds and when in posi-
tions are also required when welding on galvanized
tions such as sitting or lying, make certain the insulation is steel.
large enough to cover your full area of physical contact with
3.b. Do not use plasma arc cutting or gouging in locations near
work and ground.
chlorinated hydrocarbon vapors coming from degreasing,
1.d. Always be sure the work cable makes a good electrical con- cleaning or spraying operations. The heat and rays of the arc
can react with solvent vapors to form phosgene, a highly
nection with the metal being cut or gouged. The connection
toxic gas, and other irritating products.
should be as close as possible to the area being cut or
gouged. 3.c. Gases used for plasma cutting and gouging can displace air
and cause injury or death. Always use enough ventilation,
1.e. Ground the work or metal to be cut or gouged to a good elec-
especially in confined areas, to insure breathing air is safe.
trical (earth) ground.
3.d. Read and understand the manufacturer’s instructions for this
1.f. Maintain the plasma torch, cable and work clamp in good, equipment and the consumables to be used, including the
safe operating condition. Replace damaged insulation. material safety data sheet (MSDS) and follow your employ-
er’s safety practices.
1.g. Never dip the torch in water for cooling or plasma cut or
gouge in or under water.
CUTTING SPARKS can
1.h. When working above floor level, protect yourself from a fall
should you get a shock.
cause fire or explosion.
1.i. Operate the pilot arc with caution. The pilot arc is capable of
4.a..Remove fire hazards from the plasma cut-
burning the operator, others or even piercing safety clothing.
ting or gouging area. If this is not possible,
cover them to prevent the cutting or gouging
1.j. Also see Items 4c and 6.
sparks from starting a fire. Remember that
welding sparks and hot materials from plasma cutting or
gouging can easily go through small cracks and openings to
adjacent areas. Avoid cutting or gouging near hydraulic lines.
Have a fire extinguisher readily available.
4.b. Where compressed gases are to be used at the job site, spe-
cial precautions should be used to prevent hazardous situa-
tions. Refer to “Safety in Welding and Cutting� (ANSI
Standard Z49.1) and the operating information for the equip-
ARC RAYS can burn. ment being used.
2.a. Use safety glasses and a shield with the prop-
er filter and cover plates to protect your eyes 4.c. When not cutting or gouging, make certain no part of the elec-
from sparks and the rays of the arc when per- trode circuit is touching the work or ground. Accidental con-
forming or observing plasma arc cutting or tact can cause overheating and create a fire hazard.
gouging. Glasses,headshield and filter lens
should conform to ANSI Z87. I standards. 4.d. Do not cut or gouge tanks, drums or containers until the prop-
er steps have been taken to insure that such procedures will
2.b. Use suitable clothing including gloves made from durable not cause flammable or toxic vapors from substances inside.
flame-resistant material to protect your skin and that of your They can cause an explosion even though they have been
helpers from the arc rays. “cleaned.� For information purchase “Recommended Safe
Practices for the Preparation for Welding and Cutting of
2.c. Protect other nearby personnel with suitable non-flammable Containers and Piping That Have Held Hazardous
screening and/or warn them not to watch the arc nor expose Substances�, AWS F4.1 from the American Welding Society
themselves to the arc rays or to hot spatter or metal. (see address above).
4.e. Vent hollow castings or containers before heating, cutting or
gouging. They may explode.
4.f. Do nor fuel engine driven equipment near area where plasma
cutting or gouging.
�2�
Apr. �93
4.g. Sparks and spatter are thrown from the plasma arc. Wear
PLASMA ARC can injure.
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
7.a. Keep your body away from nozzle and
or gouging out of position or in confined places. Always wear
plasma arc.
safety glasses with side shields when in a cutting or gouging
area.
7.b. Operate the pilot arc with caution. The pilot arc is capable of
4.h. Connect the work cable to the work as close to the cutting or
burning the operator, others or even piercing safety clothing.
gouging area as practical. Work cables connected to the build-
ing framework or other locations away from the cutting or
gouging area increase the possibility of the current passing
through lifting chains, crane cables or other alternate circuits.
This can create fire hazards or overheat lifting chains or
cables until they fail.
CYLINDER may explode
if damaged.
5.a. Use only compressed gas cylinders contain-
ing the correct gas for the process used
and properly operating regulators designed
for the gas and pressure used. All hoses,
fittings, etc. should be suitable for the application and main-
ELECTRIC AND MAGNETIC FIELDS
tained in good condition.
may be dangerous
5.b. Always keep cylinders in an upright position securely
8.a. Electric current flowing through any con-
chained to an undercarriage or fixed support.
ductor causes localized Electric and
5.c. Cylinders should be located: Magnetic Fields (EMF). Cutting or gouging
� Away from areas where they may be struck or subjected to current creates EMF fields around torch
physical damage. cables and cutting machines.
� A safe distance from plasma cutting or gouging, arc weld-
ing operations and any other source of heat, sparks, 8.b. EMF fields may interfere with some pacemakers, so opera-
or flame. tors having a pacemaker should consult their physician
before cutting or gouging.
5.d. Never allow any part of the electrode, torch or any other
electrically “hot� parts to touch a cylinder.
8.c. Exposure to EMF fields during cutting or gouging may have
other health effects which are now not known.
5.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
8d. All operators should use the following procedures in order to
5.f. Valve protection caps should always be in place and hand minimize exposure to EMF fields from the cutting or gouging
tight except when the cylinder is in use or connected for circuit:
use.
8.d.1. Route the torch and work cables together - Secure
5.g. Read and follow the instructions on compressed gas cylin- them with tape when possible.
ders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in 8.d.2. Never coil the torch cable around your body.
Cylinders,â€available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202. 8.d.3. Do not place your body between the torch and
work cables. If the torch cable is on your right side,
FOR ELECTRICALLY the work cable should also be on your right side.
powered equipment. 8.d.4. Connect the work cable to the workpiece as close as
possible to the area being cut or gouged.
6.a. Turn off input power using the disconnect
switch at the fuse box before working on
8.d.5. Do not work next to cutting power source.
the equipment.
6.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s rec-
ommendations.
6.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
�3� Apr. �93
zones où l’on pique le laitier.
PRÉCAUTIONS DE SÛRETÉ
6. Eloigner les matériaux inflammables ou les recouvrir afin de
Pour votre propre protection lire et observer toutes les instructions
prévenir tout risque d’incendie dû aux étincelles.
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv-
7. Quand on ne soude pas, poser la pince à une endroit isolé de
antes:
la masse. Un court-circuit accidental peut provoquer un échauf-
fement et un risque d’incendie.
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
8. S’assurer que la masse est connectée le plus prés possible de
la zone de travail qu’il est pratique de le faire. Si on place la
a. Les circuits à l’électrode et à la piéce sont sous tension
masse sur la charpente de la construction ou d’autres endroits
quand la machine à souder est en marche. Eviter toujours
éloignés de la zone de travail, on augmente le risque de voir
tout contact entre les parties sous tension et la peau nue ou
passer le courant de soudage par les chaines de levage,
les vétements mouillés. Porter des gants secs et sans trous
câbles de grue, ou autres circuits. Cela peut provoquer des
pour isoler les mains.
risques d’incendie ou d’echauffement des chaines et des
b. Faire trés attention de bien s’isoler de la masse quand on
câbles jusqu’� ce qu’ils se rompent.
soude dans des endroits humides, ou sur un plancher met-
allique ou des grilles metalliques, principalement dans
9. Assurer une ventilation suffisante dans la zone de soudage.
les positions assis ou couché pour lesquelles une grande
Ceci est particuliérement important pour le soudage de tôles
partie du corps peut être en contact avec la masse.
galvanisées plombées, ou cadmiées ou tout autre métal qui
c. Maintenir le porte-électrode, la pince de masse, le câble de
produit des fumeés toxiques.
soudage et la machine à souder en bon et sûr état defonc-
tionnement.
10. Ne pas souder en présence de vapeurs de chlore provenant
d.Ne jamais plonger le porte-électrode dans l’eau pour le
d’opérations de dégraissage, nettoyage ou pistolage. La
refroidir.
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
e. Ne jamais toucher simultanément les parties sous tension
du solvant pour produire du phosgéne (gas fortement toxique)
des porte-électrodes connectés à deux machines à souder
ou autres produits irritants.
parce que la tension entre les deux pinces peut être le total
de la tension à vide des deux machines.
11. Pour obtenir de plus amples renseignements sur la sûreté, voir
f. Si on utilise la machine à souder comme une source de
le code “Code for safety in welding and cutting� CSA Standard
courant pour soudage semi-automatique, ces precautions
W 117.2-1974.
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie du
corps.
PRÉCAUTIONS DE SÛRETÉ POUR
3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:
LES MACHINES À SOUDER À
a. Utiliser un bon masque avec un verre filtrant approprié ainsi
TRANSFORMATEUR ET À
qu’un verre blanc afin de se protéger les yeux du rayon-
nement de l’arc et des projections quand on soude ou
REDRESSEUR
quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la peau
1. Relier à la terre le chassis du poste conformement au code de
de soudeur et des aides contre le rayonnement de l‘arc.
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
c. Protéger l’autre personnel travaillant à proximité au
bonne mise à la terre.
soudage à l’aide d’écrans appropriés et non-inflammables.
2. Autant que possible, I’installation et l’entretien du poste seront
4. Des gouttes de laitier en fusion sont émises de l’arc de
effectués par un électricien qualifié.
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan-
3. Avant de faires des travaux à l’interieur de poste, la debrancher
talons sans revers, et chaussures montantes.
à l’interrupteur à la boite de fusibles.
5. Toujours porter des lunettes de sécurité dans la zone de
4. Garder tous les couvercles et dispositifs de sûreté à leur place.
soudage. Utiliser des lunettes avec écrans lateraux dans les
�4� Mar. �93
TABLE OF CONTENTS
Page
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
Pilot Arc Discussion......................................................................................................12
Procedure Recommendations ......................................................................................12
General ..................................................................................................................12
Thin Gauge Sheet Metal ........................................................................................12
Expanded Metal .....................................................................................................13
Thick Sections of Metal ..........................................................................................13
Gouging .................................................................................................................13
In All Cases ............................................................................................................14
Suggestions for Extra Utility from the PRO-CUT System.............................................14
Maintenance Procedures ....................................................................................................15
Routine Maintenance....................................................................................................15
Troubleshooting Procedures......................................................................................15-21
Troubleshooting Guide ........................................................................................15-18
PRO-CUT 60 Status Lights Operating Modes.....................................................19-20
Procedure for Replacing P.C. Boards ....................................................................21
Wiring Diagram PRO-CUT 60.............................................................................................22
Input Supply Connection Diagrams ...................................................................................23
Cutting Torch Connection Diagram.....................................................................................24
Parts Lists......................................................................................................................Appendix
May96
�5�
for selecting a QUALITY product by Lincoln Electric. We want you
Thank You to take pride in operating this Lincoln Electric Company product
•â?¢â?? as much pride as we have in bringing this product to you!
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Model Name & Number _____________________________________
Code & Serial Number _____________________________________
Date of Purchase _____________________________________
Whenever you request replacement parts for or information on this equipment always supply the information
you have recorded above.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
�6�
SPECIFICATIONS
Type 208/230/460/1/60 K1362-1 Handheld Torch with 25 ft. (7.6m) Cable
K1362-2 Handheld Torch with 50 ft. (15.2m) Cable
230/460/1/60 K1361-1 Handheld Torch with 25 ft. (7.6m) Cable
K1361-2 Handheld Torch with 50 ft. (15.2m) Cable
460/575/1/60 K1362-3 Handheld Torch with 25 ft. (7.6m) Cable
K1362-4 Handheld Torch with 50 ft. (15.2m) Cable
K1362-5 Robotic Torch with 50 ft. (15.2m) Cable
K1362-6 Machine Torch with 50 ft. (15.2m) Cable
K1362-7 Robotic Torch with 50 ft. (15.2m) Cable
K1362-8 Machine Torch with 50 ft. (15.2m) Cable
K871-1 [25Ft.(7.6m)Cable] & K871-2 [50Ft.(15.2m)Cable]
Magnum PCT 60 Air Cooled Torch
Input Frequency 60 Hz
Output Rating 60 Amps, 115 volts, 60% Duty Cycle
60 Amps, 115 volts, Maximum Output
45 Amps, 115 volts, 100% Duty Cycle
Pilot Current 22.5 amps
Pilot Duty Cycle 25% (20 seconds out of 80 seconds)
Current Range 25-60 Amps
Maximum OCV 282 Volts
Normal OCV 250 Volts
Input Power
Standard Voltages 208/230/460/1/60 K1362-1, -2, -5, -6
Current 50/45/23 Amps
Other Voltages 230/460/1/60 460/575/1/60
K1361-1, -2 K1362-3, -4, -7, -8
Current 45/23 Amps 23/18 Amps
Idle Current 4.5 amps @ 230V Maximum
Idle Power 0.7 kW Maximum
Power Factor @ Rated Load 0.65
Net Weight
w/25 ft. (7.6 m) Cable 322 lbs/146 kg
w/50 ft. (15.2 m) Cable 329 lbs/149 kgDimensions, H x W x D
Dimensions, H x W x D 34� x 19� x 22� (864mm x 483mm x 559mm)
(includes lift bail and undercarriage)
�7�
PRODUCT DESCRIPTION
PREHEAT TEMPERATURE FOR
The PRO-CUT® 60 is a constant current, single range, PLASMA CUTTING
continuous control plasma cutting system. It provides
excellent starting characteristics, cutting visibility and Preheat temperature control is recommended for opti-
arc stability. The torch has a patented safety mecha- mum mechanical properties, crack resistance and
nism which insures that the consumables are in place hardness control. This is particularly important on
before cutting or gouging. This is extremely important high alloy steels and heat treated aluminum. Job con-
due to the high voltages involved. ditions, prevailing codes, alloy level, and other consid-
erations may also require preheat temperature con-
The PRO-CUT 60 comes standard with air regulator, trol. The following minimum preheat temperature is
coarse air filter, oil coalescing filter, and pressure recommended as a starting point. Higher tempera-
gauge. The Pro-Cut 60 comes ready to use with the tures may be used as required by the job conditions
torch attached. Machines equipped with handheld and/or prevailing codes. If cracking or excessive
torches are available with either 25 ft. (7.6m) or 50 ft. hardness occurs on the cut face, higher preheat tem-
(15.2m) torch cable. The undercarriage is standard perature may be required. The recommended mini-
and is shipped assembled except for the handle. The mum preheat temperature for plate thickness up to 1/2
machine is capable of cutting with nitrogen or air. inch (12.7m) is 70 (°F) (21.1°C).
Nitrogen is used to cut aluminum and other nonfer-
rous metals.
USER RESPONSIBILITY
The PRO-CUT is controlled by a microprocessor-
Because design, fabrication, erection and cutting vari-
based system. The machine performs rudimentary
ables affect the results obtained in applying this type
self troubleshooting when powered up, which aids in
of information, the serviceability of a product or struc-
field servicing.
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. Some adjustments to procedures
may be necessary to compensate for unique individ-
ual conditions. Test all procedures duplicating actual
field conditions.
�8�
INSTALLATION HIGH FREQUENCY INTERFERENCE
PROTECTION
SAFETY PRECAUTIONS
Since the spark gap oscillator in the high frequency
q Read the safety precautions at the beginning of
generator in the machine is similar to a radio transmit-
this Operator's Manual before proceeding.
ter, improper machine installation can result in radio
q Only personnel that have read and under-
stood this Operator’s Manual should install and and TV interference or problems with nearby electron-
operate this equipment. ic equipment.
q Machine must be connected to system ground per
any national, local or other applicable electrical Radiated interference can develop in the following
codes. four ways:
q The power switch is to be in the “OFF� position when
connectiong power cord to input power.
(1) Direct interference radiated from the machine.
WARNING (2) Direct interference radiated from the cutting
leads.
TURN THE INPUT POWER OFF USING THE
DISCONNECT SWITCH AT THE FUSE BOX
BEFORE ATTEMPTING TO CONNECT THE (3) Direct interference radiated from feedback into
INPUT POWER LINES. the power lines.
� Only qualified personnel should perform this installa- (4) Interference from reradiation of “pickup� by
tion. ungrounded metallic objects.
� Turn the power switch on the PRO-CUT “off� before Keeping these contributing factors in mind, installing
connecting or disconnecting output cables. equipment per the following instructions should mini-
mize problems.
� Connect the PRO-CUT grounding terminal located
on the side of the case back to a good electrical (1) Keep the machine power supply lines as short as
earth ground. possible.
------------------------------------------------------------------------
(2) Keep the work and torch leads as short as possi-
ble and as close together as possible. Lengths
LOCATION
should not exceed 50 ft. (15.2 m). Tape the
leads together when practical.
Place the PRO-CUT where clean cooling air can
freely circulate in through the front intake and out
(3) Be sure the torch and work cable rubber cover-
through the rear louvers. Dirt, dust or any foreign
ings are free of cuts and cracks that allow high
material that can be drawn into the machine should be
frequency leakage.
kept at a minimum. Failure to observe these precau-
tions can result in excessive operating temperatures
(4) Keep the torch in good repair and all connections
and nuisance shutdown of the machine. Before plan-
tight to reduce high frequency leakage.
ning the installation, read the section entitled “High
Frequency Interference Protection�.
(5) Keep all access panels and covers securely in
place
A source of clean, dry, compressed air or nitrogen
must be supplied to the PRO-CUT. Oil in the air is a
NOTE: The machine frame MUST also be grounded -
severe problem and must be avoided. The supply
see CAUTION under “Input Connection�, sec-
pressure must be between 70 and 120 psi (482 and
tion. The work terminal ground does not ground
827 kPa). The flow rate is approximately 4.7 cfm (133
the machine frame.
l/min.). Failure to observe these precautions could
result in excessive operating temperatures or damage
(6) When the machine is enclosed in a metal build-
to the torch.
ing, several good earth driven electrical grounds
around the periphery of the building
are recommended.
Failure to observe these recommended installation
procedures may cause radio or TV interference prob-
lems and result in unsatisfactory cutting or gouging
performance resulting from lost high frequency power.
�9�
INPUT CONNECTIONS WARNING
WARNING ELECTRIC SHOCK can kill.
� Make certain that the input power
ELECTRIC SHOCK can kill.
is electrically disconnected before
� Disconnect input power before
removing the screws that hold the
proceeding.
removable rear panel in place.
� Have a qualified electrician make
------------------------------------------------------------
the input connections.
Have a qualified electrician connect the input leads to
� Be sure the voltage, phase and frequency
L1 and L2 of the terminal block in accordance with
of the input power is as specified on the
any National Electrical Code, all local codes and the
machine nameplate. connection diagram located on the inside of the cover.
------------------------------------------------------------ Use ferrules provided (S19117-1) for #10 wire. No
ferrule is required for #8 wire. Tighten screws to 16
Before starting the installation, check with the local
in/lbs. (1.8 N.M.). See below.
power company if there is any question about whether
your power supply is adequate for the voltage,
amperes, phase, and frequency specified on the
machine nameplate. Also be sure the planned instal- .50"
lation will meet the any National Electrical Code and (12.7mm)
local code requirements. This machine may be oper-
ated from a single phase line or from one phase of a
two or three phase line.
Strip Required for #10 (5.3mm2) Wire
Models that have multiple input voltages specified on
the nameplate (e.g. 208/230/460) are shipped con-
nected for the highest voltage. If the machine is to be
operated on the lower voltage, it must be reconnected
according to the instructions on the inside of the
removable panel in the center of the rear panel.
Machine supply line entry provision is next to the
removable panel.
Place Ferrule (S19117-1) Over Wire as Shown
Before Insertion into Machine Terminal Block.
For #10 (5.3mm2) AWG Wire Only
RECOMMENDED WIRE SIZE FOR PRO-CUT INPUT CONNECTIONS
Based on U.S. National Electrical Code Ambient Temperature 30ËšC or Less
Wire Size
(Copper, 75ËšC)
Rated Input Fuse
Voltage 2 Input Wires 1 Grounding Wire Size
Less than 230 #8 (8.4mm2) #10 (5.3mm2) 50Amp
230 #8 (8.4mm2) #10 (5.3mm2) 50Amp
460 #10 (5.3mm2) #10 (5.3mm2) 25Amp
Greater than 460 #10 (5.3mm2) #10 (5.3mm2) 25Amp
� 10 �
(6.3 mm) NPT thread. Tighten the air fitting to prevent
CAUTION leakage but do not overtighten. The use of Teflon
tape to seal the connection is recommended.
The frame of the machine must be grounded. A
ground terminal marked with the symbol located at Nitrogen from cylinders may be used with this
the left side of the input box is provided for this pur- machine. The cylinder of nitrogen gas must be
pose. See the U.S. National Electrical Code for details equipped with a pressure regulator. No more than
on proper grounding methods. Follow other grounding 120 psi (827 kPa) may be supplied to the regulator on
instructions per the paragraph under “High Frequency the machine. Install a hose between the regulator on
Interference Protection�. the gas cylinder and the gas inlet on the machine.
On multiple voltage input machines, be sure the
reconnect panel is connected per the following
OUTPUT CONNECTIONS
instructions for the voltage being supplied to the
machine. See Figure 1 in the back of this manual.
WARNING
HIGH FREQUENCY SHOCK CAN
CAUSE INJURY OR FALL.
� Failure to follow these instructions can cause imme-
� Keep the cutting torch and cables in
diate failure of machine components.
good condition.
------------------------------------------------------------------------
� Secure yourself in position to avoid a fall.
The PRO-CUT is shipped connected for the highest
----------------------------------------------------------------------------
nameplate input voltage. To change this connector
for a different input voltage, reconnect the power Torch Connection
straps to their respective terminals corresponding to
the input voltage used.
The PRO-CUT comes factory equipped with a cutting
torch.
Fuse the input circuit with the recommended super lag
fuses. Choose an input and grounding wire size
Pictures of the torch along with the required replace-
according to local codes or use the Input Connection
ment parts are shown in the parts lists in the back of
table. “Delay type�(1) circuit breakers may be used in
this manual. The ends of the cable to be connected to
place of fuses. Using fuses or circuit breakers smaller
the power source are unique. Follow the applicable
than recommended may result in “nuisance� tripping
instructions as given in Figure 2 in the back of this
from machine inrush currents even if not cutting or
manual.
gouging at high currents.
(1)
Also called “inverse time� or “thermal/magnetic� circuit breakers; circuit Work Cable and Clamp Installation
breakers which have a delay in tripping action that decreases as the magni-
tude of the current increases.
WARNING Work cable
CYLINDER may explode if damaged
� Keep cylinder upright and chained to a
fixed support.
� Keep cylinder away from areas where it
may be damaged. Work clamp
� Never lift equipment with cylinder attached.
Attach the work clamp to the work cable (which
� Never allow the cutting torch to touch cylinder.
extends from the front of the machine) as shown.
� Keep cylinder away from live electrical circuits.
Tighten nut and bolt securely.
� Maximum inlet pressure 120 psig (827 kPa).
------------------------------------------------------------------------
OPERATING INSTRUCTIONS
AIR INPUT CONNECTIONS
Sequence of events:
A source of clean compressed air or nitrogen must be
supplied to the PRO-CUT. The supply pressure must
A. Turn on the line power.
be between 70 and 120 psi (482 and 827 kPa). The
flow rate is approximately 4.7 cfm (133 l/min). Oil in
B. Connect the air supply to the machine.
the air is a very severe problem and must be avoided.
C. Turn the power switch on.
Remove the plastic thread protector from the regulator
input port (located on the back of the machine). Use a
-The green “Power On� LED should begin to
suitable gas connection fitting to make the connection
glow.
to the available air supply. The input port is a 1/4�
� 11 �
-The fan should start. � After the problem is found, reset the machine by
pressing the “Safety Reset� button. (It is
-If the “Safety� LED is glowing, push the “Safety possible for electrical noise to trip the safety cir-
Reset� button. If there is no problem, the LED cuit on rare occasions. This should not be a
will go off. If there is a problem, refer to Step F regular occurrence.)
and the Troubleshooting Guide.
� If the machine does not reset or continues to
D. Set the Purge/Run switch to Purge. trip, consult the Troubleshooting Section.
Pilot Arc Discussion:
-The air should start.
The PRO-CUT has a smooth, continuous pilot arc.
-The “Air Pressure� LED should be lit.
The pilot arc is only a means of transferring the arc to
the workpiece for cutting. Repeated pilot arc starts, in
-Adjust the air regulator for 60 psi (413 kPa),
rapid succession, is not recommended as these starts
minimum while air is flowing.
will generally reduce consumable life. Occasionally,
the pilot arc may sputter or start intermittently. This is
E. Set the Purge/Run switch to Run.
aggravated when the consumables are worn or the air
pressure is too high. Always keep in mind that the
-The air will continue to run for 20 seconds of
pilot arc is designed to transfer the arc to the work-
postflow. If the trigger is activated within this
piece and not for numerous starts without cutting.
time period, the pilot arc will immediately start.
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 Procedure Recommendations
taken and pull the trigger.
When properly used, plasma arc cutting or gouging is
-The air will flow for a preflow time of 2 seconds a very economical process.. Improper use will result
and the pilot arc will start. (This is true unless in a very high operating cost.
the machine is in postflow, then the preflow time
is skipped.)
General
-The “Output ON� LED will light.
� Follow safety precautions as printed inside the
-The pilot arc will run for 2.5 seconds and shut off operating manual and on the machine.
unless it is brought in contact with the work and
the arc is transferred. � Use the drag cup when hand cutting at medium
or high output.
-When the arc is transferred, cutting begins.
Finish the cut to be made and release the trigger. � Use the proper cutting or gouging procedures
referred to in procedures guideline.
G. When the trigger is released, the arc will stop.
� Use the shield cup with mechanized torches or
-The air will continue to run for 20 seconds of when hand cutting at low output.
postflow. If the trigger is activated within this
time period, the pilot arc will immediately restart.
Thin Gauge Sheet Metal:
H. If the “Safety� LED lights at any time, check the following:
Output set below mid-range.
WARNING
ELECTRIC SHOCK CAN KILL. � The torch should be dragged on the metal sur-
� Turn off machine at the disconnect face, touching the nozzle lightly to the surface
switch on the front of the machine after piercing a hole. Current control should be
before tightening, cleaning or replacing set in the yellow range only.
consumables.
---------------------------------------------------------------------------- � The S24114 Drag Cup should not be used at
very low outputs. It may cause erratic arc
� Check the assembly of the torch consumables.
action.
If they are not properly in place then the
machine will not start.
� 12 �
� The .035� (0.8mm) nozzle may be used for a the output control is in the blue or red regions is
fine cut. Larger nozzles will work and provide in special tight corners. Always hold at least a
longer life at the expense of a larger cut. 1/8� (3.2mm) standoff in those situations and
use the S18817 shield cup.
� Do not allow the torch cable or body to contact
hot surface. � Set the current to the minimum necessary to
make the cut.
� The best quality cut is obtained by reducing the
current to a level that is adequate for the maxi- � Use the .052� or .042� (1.2 or 1.0mm) nozzle
mum travel speed. size. DO NOT use the .035� (0.8mm) nozzle.
� Aluminum, copper and other nonferrous metals � Pierce the plate by slowly lowering the torch
typically require more current than the same onto it at an angle of about 30° to blow the
thickness of steel. Treat these as a thicker sec- dross away from the torch tip and slowly rotate
tion of steel if good results are not obtained. the torch to a vertical position as the arc
becomes deeper.
Expanded Metal:
� Where possible, start the cut from the edge of
the workpiece.
Output set near mid-range.
� Keep moving! A steady speed is necessary.
� Cut it as you would light gauge sheet metal.
Do not pause.
� Expanded metal is pilot arc intensive. After
� Do not allow the torch cable or body to contact
about 30 seconds of cutting, the pilot arc will
hot surfaces.
change from a bright continuous arc to a discon-
tinuous one which will sputter slightly. It will stay
in this mode as long as metal has been cut in
Gouging:
the previous 5 seconds. If metal is not cut in the
previous 5 seconds, the arc will shut off and the
Output set to maximum.
machine will go into postflow.
� Use the gouging nozzle S18497-4
� If the trigger is continuously pressed and
released to obtain the bright pilot arc for long
� Use the Shield Cup.
periods of time, the machine will go into pilot arc
duty cycle limit. This is a 20 seconds out of 80
� Bring the torch slowly towards the work at about
seconds pilot duty cycle. The pilot arc is dis-
a 30° angle as if piercing the plate. Blow the
abled in the limit period. Pilot arc duty cycle
molten metal away from the torch.
limit is indicated by alternately flashing “OUT-
PUT ON� and “FAULT� LED’s.
� Do not touch the nozzle to the work.
� Placing a thin piece of scrap sheet metal above
� The air pressure may be raised to about 75 psi
the area to be cut and cutting through both can
(517 kPa) to aid in metal removal.
make the job easier.
� This process will blow a lot of molten metal and
� Do not allow the torch cable or body to contact
dross. BE CAREFUL! Blow the dross away
hot surfaces.
from the torch, away from the operator and
away from flammable objects.
Thick Sections of Metal
� Do not allow the torch cable or body to contact
Output set above mid-range. hot surfaces.
� The best quality and consumable life will be � Performance is similar to air carbon arc gouging
obtained by holding the torch nozzle off the sur- with a 1/8� (3.2mm) carbon electrode.
face about 1/8� (3.2mm). Output control should
be sent in the red range only. Do not touch the
nozzle to the work or carry a long arc.
� Use the S24114 Drag Cup to protect the torch.
The only reason not to use the Drag Cup when
� 13 �
In All Cases: � The PRO-CUT will cut with consumables that are
worn considerably. Many competitive systems
require replacement consumables long before a
� Do not pause when cutting or gouging the
PRO-CUT system does. This is because of the solid
metal. This is not necessary and causes opera-
state current regulation that the PRO-CUT has. Also,
tional difficulty. Pausing at the edge of the work-
the safety reset circuit provides a means of extending
piece causes poor consumable life and erratic
nozzle life. Sometimes a small piece of material
operation.
breaks off the electrode and bridges the gap between
the nozzle and the electrode. In a competitive unit,
� Always position the torch in the best way to
this would often result in the destruction of the elec-
keep dross and hot air from burning back into it.
trode and nozzle due to overheating. This will result
in the tripping of the PRO-CUT safety circuit. When
� Do not carry a long arc. This may trip the safety
this happens, turn the power off, remove the nozzle
or fault circuits and wears consumables rapidly.
and scrape any debris from its inside cavity with a
piece of sturdy wire or a suitable drill bit. Replace the
� Do not drag the nozzle above the mid-range setting.
nozzle, turn on the power and continue cutting.
Always hold a standoff of 1/8� above mid-range.
� The electrode has a hafnium insert at the tip which
� Use a Drag Cup where possible but only when
greatly prolongs the life of the consumable. When
the current is in the blue or red ranges. Drag
that insert has been consumed, the machine will
the nozzle in the yellow range. The use of the
automatically turn off output and lock up in “FAULT�.
Drag Cup at low currents (in the yellow range)
At this point, replace the electrode and the nozzle; it
may cause problems. Proper use of the Drag
is not recommended to continue cutting with an elec-
Cup is the best way to get maximum nozzle and
trode that has consumed all of its hafnium.
consumable life.
� Use of the nozzle with the largest orifice size that pro-
� Use the proper machine setting. Running the
duces acceptable cutting results will maximize con-
system at maximum output will not produce the
sumable life. Procedures given are all based on a
best cutting performance in most situations.
.042" (1.0mm) orifice size. Smaller orifice sizes con-
strict the arc more, raising the energy density and
� Use the proper cutting or gouging procedures
therefore the temperature. Larger orifice sizes have
referred to in procedures guideline.
an opposite effect. Small orifice nozzles run hotter
and wear faster than large orifice nozzles but pro-
� Use the nozzle with the largest orifice size that
duce a finer cut with less kerf width. There is a cer-
gives an acceptable cut. This will improve parts
tain current where each orifice size becomes unsta-
life. Never use the .035� (0.8mm) nozzle at out-
ble because it runs too hot. Never use the smallest
puts above the yellow range.
.035� (0.9mm) orifice size at outputs above the yel-
low range because it will be quickly destroyed.
Suggestions for Extra Utility from the
PRO-CUT System: � The PRO-CUT 60 is capable of operation with a 50 ft.
(15.2m) plasma torch. Pilot arc operation may be
� In some cases where moderate or thin sections slightly degraded with this torch installed. Sputtering
are being cut, higher air pressure may give bet- may occur after the pilot arc is established and occa-
ter consumable life. At pressures about 80 psi sionally the pilot arc may not light after the trigger is
(551 kPa), the pilot arc may sputter. This may depressed*. Keep in mind that the condition of the
be an annoyance but it will not damage the consumables and air pressure level have a large
torch or power source. 60 psi (413 kPa) mini- impact on pilot arc ignition.
mum while air is flowing is the recommended
pressure because it is the minimum necessary * Neither cutting performance nor machine reliabili-
to provide proper cooling in all situations. Feel ty will be lessened by this condition.
free to experiment with higher pressures (not to
exceed 120 psi (827 kPa) at the regulator input).
WARNING
ELECTRIC SHOCK CAN KILL.
� Turn off machine at the disconnect switch on the
front of the machine before tightening, cleaning or
replacing consumables.
------------------------------------------------------------------------
� 14 �
MAINTENANCE PROCEDURE TROUBLESHOOTING PROCEDURES
ROUTINE MAINTENANCE
WARNING
WARNING ELECTRIC SHOCK CAN KILL.
ELECTRIC SHOCK CAN KILL. BEFORE PERFORMING ANY MAINTE-
BEFORE PERFORMING ANY MAINTE- NANCE THAT REQUIRES OPENING
NANCE THAT REQUIRES OPENING THE CASE OF THE POWER SOURCE:
THE CASE OF THE POWER SOURCE:
� Disconnect input power to this machine at the
� Disconnect input power to this machine at the Disconnect switch.
Disconnect switch.
� Do not touch electrically live parts or internal wiring.
� Do not touch electrically live parts or internal wiring.
� Only qualified personnel should service this
� Only qualified personnel should service this machine.
machine. ------------------------------------------------------------------------
------------------------------------------------------------------------
HOW TO USE THIS GUIDE: Carefully read through
each applicable section listed on the following pages.
1. Keep the cutting or gouging area and the area
Remember that most problems are caused by improp-
around the machine clean and free of com-
er setup, such as switch settings, control settings, etc.
bustible materials. No debris should be allowed
to collect which could obstruct air flow to the
If you believe the set up is correct and the trouble still
machine.
exists, first check for the obvious: input power, blown
fuses, loose PC board connectors, broken wires and
2. Every few months, blow the dust off the air
the like. The sections listed on the following pages
intakes and louvers with compressed air. Also,
are intended to help you find the less obvious sources
blow off the components in the upper compart-
of trouble.
ment with compressed air.
3. Check the air regulator filters to be sure they do
not become clogged. The first stage of the air
filter on the machine is self draining and will
stop most of the water in the air line. The sec-
ond stage of the filter is also self draining and
will stop almost all of the oil in the line as well as
particulate matter. Both stages will drain auto-
matically when the flow rate changes rapidly.
4. Check the filter elements every several months
to see if they are clogged (weekly in very dirty
environments). Replace if necessary.
5. Inspect the cable periodically for any slits or
puncture marks in the cable jacket. Replace if
necessary. Check to make sure that nothing is
crushing the cable and blocking the flow of air
through the air tube inside. Also, check for
kinks in the cable periodically and relieve any so
as not to restrict the flow of air to the torch.
WARNING
ELECTRICAL SHOCK CAN KILL.
� Turn off machine at the disconnect switch at the
back of the machine before tightening, cleaning or
replacing consumables.
------------------------------------------------------------------------
Change consumables as required.
� 15 �
SYMPTOM CHECK
No LED’s light when the power switch is turned on. 1. Check the input power to be sure it is on.
2. Check the power line fuses and machine
connection.
3. Replace line switch.
TORCH WILL NOT LIGHT 1. Low air pressure results in a "no start" condition.
The “MACHINE ON� LED is lit, but there is no "Air Pressure" LED must be lit when air is
response when the trigger is pulled. flowing. Set the machine in purge mode.
The air will turn on. Set the regulator on the
back of the machine for 60 psi minimum. If the
"AIR PRESSURE" LED does not light, raise the
pressure slightly. If the inlet pressure is greater
than 75 psi and the LED is not lit when air is
flowing, there is a leak or the air filters in the
regulator assembly are clogged.
2. Check the "SAFETY" LED. If it is lit, check the
torch consumables and press the "SAFETY
RESET" button.
3. Check the air supply to the machine. If the air
does not flow, the machine will not start.
4. Check the operation of the air solenoid by
switching the machine to "PURGE". The air
should begin to flow and if the pressure is suffi
cient, the "AIR PRESSURE" LED will light.
Return to "RUN" mode. If air does not flow,
check the solenoid by applying 115 VAC to its
input leads. If it is bad, replace the solenoid, or
else replace the control board.
The air begins to flow, the “OUTPUT ON� LED lights 1. Check the torch consumables to be sure they
for a brief period, but no arc is established. are in tight, not dirty or greasy, and in good
shape. Replace the consumables if necessary.
2. Check that CR2 engages.
3. Check for high frequency at the spark gap.
4. Check the high frequency spark gap located
inside the right panel of the machine. It should
be set at .060� (1.52mm) DISCONNECT ALL
POWER BEFORE ADJUSTING THE HIGH
FREQUENCY CIRCUIT.
5. Blow off the components in the upper compart-
ment with compressed air.
6. Check pilot to 391 for 2 ohm resistance.
7. Check 2 ohm 300 watt resistor.
8. Replace Control PC Board.
� 16 �
SYMPTOM CHECK
The arc starts but sputters badly. 1. Check the torch consumables to be sure they
are tight, not dirty or greasy and in good shape.
Replace if necessary.
2. Check air supply for oil or a great deal of water.
If there is oil or a great deal of water, the air
must be filtered or the machine switched to
nitrogen or bottled air.
3. Check the air pressure. The pressure must be
60 psi (413 kPa) minimum while air is flowing.
The "Air Pressure" LED must be lit.
The “THERMAL� LED is lit. The “FAULT� 1. The machine is overheated. Allow it to cool and
LED is blinking. reset. The air intakes of the machine must not
be blocked, or this will become a nuisance.
The “FAULT� LED is lit 1. The Fault circuit monitors the torch to see if it is
shorted as well as internal machine failures.
2. Check the torch consumables to see if they are
melted together or are simply touching each
other. Tighten, clean or replace. See
“Suggestion for Extra Utility from the PRO-CUT
System�.
3. Check the torch cab le to see if it is cut or
punctured. Replace.
4. Turn off the machine and turn it back on. If the
“FAULT� LED will not stay off when you try to
cut again and there is no problem with the torch,
then something has failed in the machine and
the machine should not be left on.
4a) Check electrode to pilot for short.
4b) Check air flow.
4c) Check the power board. During preflow,
there should be no voltage between work and
electrode and at end of preflow open circuit
voltage should be present. Replace if bad.
5. Replace control PC board.
Alternating “AIR/FAULT� LED lights. 1. Replace control PC board.
The “OUTPUT ON� and “FAULT� LED’s 1. The pilot arc duty cycle has been exceeded.
blink in alternating order. The machine will cool down and the lights will
quit blinking in about 20 seconds. The pilot arc
is limited to 20 out of 80 seconds except in
special circumstances such as cutting
expanded metal. (See the section on expanded
metal in the Operating Section.)
Airflow will not shut off. 1. Check harness 1J7 (C2) and 3J7 (H6).
� 17 �
SYMPTOM CHECK
The “SAFETY� LED is lit. 1. The machine will not operate. The machine
senses that the nozzle is not in place, or the
operator could be exposed to dangerous volt
ages if the machine were allowed to operate.
2. Check the nozzle to be sure it is tightly in place.
3. Check the torch consumables to see if they are
melted together or are simply touching each
other. Tighten, clean or replace. See
“Suggestion for Extra Utility from the Pro-Cut
System�.
4. Check the torch cable to see if it is cut or punc-
tured. Replace.
5. Check to see that the torch is hooked to the
machine properly.
6. Push the "SAFETY RESET" button, the LED
should go out. If the LED does not go out, the
thermal sensor in the torch head has actuated.
Note that the thermal sensor exists in the hand
held torches but not the machine or robotic
torches. This sensor prevents the torch from
melting, and should not trip in normal operation.
Wait several minutes until the torch head is cool,
and press the reset button. If the LED does not
go out, check step 2 again before proceeding.
Read the procedures section of this manual for
instruction in proper cutting technique.
7. This circuit rarely trips on power up or because
of noise. If the circuit can be reset, it is Ok to
continue operation.
8. Check the continuity between pins 1 & 3 in the
plastic amp connector on the torch assembly.
This is the 4-pin connector that plugs into the
power source. If the safety circuit is working
properly, there will be continuity when the nozzle
is in place and no continuity when the nozzle is
removed. When the nozzle is in place, there
must be continuity between pins 1 & 3 and the
torch pilot lead. Replace the torch if the continu
ity measurements are not as described, or else
replace the control board.
No OCV when 2 and 4 are closed. 1. 190 VAC across H1 and H2.
2. 250V SCR PC board positive/negative
3. Check across 31/32 for 110 VAC.
4. Replace Control PC board.
� 18 �
PRO-CUT 60 STATUS LIGHTS OPERATING MODES
STATUS
LIGHTS CONDITION SUGGESTIONS
MACHINE ON Should always be on when machine is on. Normal
OUTPUT ON On when there is voltage potential at the Normal
torch (cutting or pilot).
OUTPUT ON is blinking alternately with
AIR PRESSURE when power is first There is a problem with the microprocessor,
applied to machine. replace the Control PC board.
If OUTPUT ON is blinking alternately
with FAULT, the pilot arc duty cycle is
exceeded. Wait for machine lights to stop blinking.
AIR PRESSURE On whenever the air pressure is above 60 Normal conditions are purge, preflow,
psi (413 kPa), there is an error condition postflow and cutting.
mentioned above where air will turn on.
The air will turn on for a brief time when
power is first applied to machine.
THERMAL Should normally be off. If on, wait for machine to cool down.
FAULT Light on. At end of preflow, machine Check consumables, replace as needed.
checks to see if the torch is shorted and if Check torch cable to see if it is punctured
it can fire the transistors. or cut.
Light blinking. If cutting tried with air No air connected to machine, air pressure
pressure less than 60 psi (413 kPa) while set too low, or air leak in system.
air is flowing, the machine will wait for air
pressure to become greater than 60 psi
(413 kPa).
Light blinking alternately with OUTPUT Pilot arc duty cycle has been exceeded.
ON. Wait for machine lights to stop blinking.
Light started blinking during cutting or If cutting or gouging with standoff more than
gouging. There is an overcurrent condition 1/8� (3.2mm) at high range of machine and
caused by a surge of current the machine nozzle is accidentally touched to work, shorten
was not designed to handle. Release the stickout, or use Drag Cup. Check consumables
trigger and resume cutting or gouging. to see if electrode melted to nozzle.
Light blinking with THERMAL light on. Wait for machine to cool.
� 19 �
STATUS
LIGHTS CONDITION SUGGESTIONS
SAFETY It is possible that this light could turn on If machine can be reset, it is OK to continue
when power is first applied to machine. operation.
The nozzle is not in place. Securely fasten nozzle in place.
While cutting or gouging if the voltage By pressing reset, the machine will be
between the nozzle and the work is too functional. This occurs most often when the
high, it will put the machine into SAFETY. consumables are wearing out. By removing
the hafnium that builds up on the inside of the
nozzle, it is possible to extend the life of the
consumables.
If the cable is punctured or cut, it can trip By pressing reset, it will clear the SAFETY.
the SAFETY When cutting is tried again, the machine will
either go into FAULT or SAFETY; until that time,
the machine will not indicate a malfunction
condition.
The torch may be overheated. There is Wait for the torch to cool down, and
a thermal sensor in thehand-held torch reset the safety circuit. Read the
heads to protect it during abusive use. procedures section of this manual for
It will not trip in normal use - even if it is instruction in proper cutting technique.
abused heavily.
� 20 �
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.
� Only qualified personnel should service this
machine.
------------------------------------------------------------------------
Before replacing a PC board which is suspected of
being defective, visually inspect the PC board in ques-
tion for any damage to any of its components and
conductors on the back of the board.
If there is no visible damage to the PC board, install a
new one and see if this remedies the problem. If the
problem is remedied, reinstall the old PC board to see
if the problem still exists. If it does no longer exist
with the old PC board:
1. Check the PC board harness conductor pins for
corrosion, contamination or looseness.
2. Check leads in the plug harness for loose or
intermittent connection.
If PC board is visibly damaged electrically (compo-
nents burned, copper traces opened or damaged),
before possibly subjecting the new PC board to the
same cause of failure, check for possible shorts,
opens or grounds caused by:
1. Frayed or pinched lead insulation.
2. Poor lead termination, such as a poor contact or
a short to adjacent connection or surface.
3. Two or more leads shorted together.
4. Foreign matter or interference behind the PC
boards.
If PC board is visibly damaged mechanically (such
as a part vibrated off or was crushed), inspect for
cause, then remedy before installing a replacement
PC board.
If there is damage to the PC board if replacing PC
board corrects problem, return it to the local Lincoln
Electric Field Service Shop.
� 21 �
WIRING DIAGRAM - PRO-CUT 60 (SINGLE PHASE)
230 V
208 V TO SUPPLY
TO SUPPLY
4 2A
1
POS-D LINES
OPTION LINES
9 4A
32D OUTPUT
4 SAFETY
BOARD
2
July96
403 OPTION
31D 3 CONTROL
RESET L1 2 1
1
STATUS BOARD L1 3
2 T1
1
1 3
404 T1
7 HARNESS
321D 5 OPTIONAL
76
5
J19
400D 6 S3
J9
75 CNC & GMF
10 CW L2
L2 4
5
2
4
5
2D 2 6 T2
10K
7 T2
401
J23 3 INTERFACE
4D 8 3
8 402 1 R1
KIT
2B
6
212D 10
8 7
4B
1 326
11
76D 2
8
1237564
POS
1 77D
2 325
J25 405
2
324D 9 76 77
75
NEG
3 TS1
76B S1
12
77D TS1 S1 TO PRIMARY
216
212 214 212D TO PRIMARY
76C COILS
215
211 213 218
OPTIONAL TO GROUND
TO GROUND
400D COILS
OPTION
TERMINAL OPTION PER NATIONAL
PER NATIONAL
2A
4A
2B
4B
POS
405
NEG
75
76
401
JUMPER
402
403
404
STRIPS JUMPER ELECTRICAL CODE
ELECTRICAL CODE
J2
J8
321D OPTION
JUMPER
324D 460 V
76D TO SUPPLY
J10
76B 1 LINES
2
36 HALF OF OPTION
45
12 6 3 14 7 8 4 9 5 10 11
OPTIONAL
REMOTE
31D
76C JUMPER J12
REMOTE/LOCAL
L1
SWITCH 5 1 3 1
2
T1
SV1
2 4J12 1J12
38
2
319
J2
324 15 L2 5
T2 4
2
AIR
LOCAL 323 16
3 SOLENOID
335 31
322 13
319 J10
J8
1
321
CR2
36
1
PURGE/RUN
C507
1
SWITCH 32D
CONTROL BOARD TS1 S1
.0047 TO PRIMARY
(PURGE IS 31
4
2 34
3000V COILS
OPEN) 32
6
3 TO GROUND
319
4 PER NATIONAL
5 J3 ELECTRICAL CODE
6J12 3J12
PRIMARY 6
COIL CR2
7 208/230/460V OR 230/460V MAIN TRANSFORMER
THERMOSTAT
8 J5
J6
HALF OF (POS-D)
C508
2
9
J12 OPTION J7 J4 .0047
10 1
JUMPER
3000V
PRESSURE 4D
SWITCH 40
31
35
2
23
14 8 10 4 3124
639 576834
5 11 12 1 7 2D
HI VOLTAGE
TRANSFORMER
J4, J7, J20,
37
384 J12
222
R W 338 385 J2,J10,J21 J5, J9
386 383 221 4 J22, J25
332 C1 336 2
40
L502
337 L501
335
3 TOP 4
PRI.
8 306
W
R
� 22 �
P23
J5 J8
J6, J23
J3, J19
SPARK
305
OPTION GAP CONNECTOR CAVITY NUMBERING SEQUENCE
1324
JUMPER
H6 32
C2 N.A. (VIEWED FROM COMPONENT SIDE OF BOARD)
FAN C1
31
307
332 AMPHENOL
H3 CONNECTION
338
1 1 460/575V MAIN TRANSFORMER
FROM TORCH
12VAC 3
6 H4
7
H3
CENTER
R5
H4 12W 460 V
TO SUPPLY
PRI.
LINES
13 24
42
3 3156
4 H6
304
24VAC C504
C2 L1 1 3 1
2
T1
2800
J22 TORCH
300V
J21
31 115 L2
NEG E 5
BULKHEAD 6
71 T2 4
C1 2
BOTTOM
A1
A2
VAC L503 L504
24VAC 71
PRI. CONNECTOR
HI FREQ
6 32
ASBLY.
H1
H2 C505 72
NEG
2 2 PILOT
389
MAIN SEC. +
+
H2
TS1 S1
H1 TO PRIMARY
71
BYPASS COILS
389
C506
G2 G1 TO GROUND
40 BOARD
460/575V 208/230/460V
.0047 PER NATIONAL
40 POS 389
3000V
MAIN TRANSFORMER ELECTRICAL CODE
2.5K
R8
CR2
5W
NEG
K2 K1
C 575V
40
GENERAL INFORMATION TO SUPPLY
37
POS
B
SEMICONVERTER LINES
391
ELECTRICAL SYMBOLS PER E1537 40 C
MODULES 5
40
37 100W 391
R3
L1 3
T1 1
2
B
RESISTORS = OHM/WATT (1/2 WATT UNLESS 50W
40 R7
2
OTHERWISE SPECIFIED)
R2
G1 L2 5
387 T2 4
300W 6
40
B
G2
CAPACITORS = MFD/VOLTS
34 12
NOTES
TRANSISTOR
L1
MODULE
AUXILIARY COILS NUMBER 3 IS CONNECTED TO THE NOZZLE POS
N.A.
40
J20 POS
POWER BOARD TS1 S1
H3-H4 12 VAC (PILOT LEAD AT THE TORCH). TO PRIMARY
COILS
H6-C2 24 VAC N.B. 6, 7, & 8 APPEAR ON TRIPLE VOLTAGE
TO GROUND
& 208V SINGLE MACHINES ONLY
31-32 115 VAC PER NATIONAL
ELECTRICAL CODE P/N25099
W WORK
C1-32 24 VAC
L10294
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside
the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number..
INPUT SUPPLY CONNECTION DIAGRAM
FOR DUAL VOLTAGE MACHINE. LINK POSITIONS
LINK
575 V., 60HZ.
NOTE: MACHINES ARE SHIPPED FROM FACTORY CONNECTED
FOR 575 VOLTS GND.
L1 L2
USE FERRULE
#10 AWG ONLY
HIGH VOLTAGE
LINK POSITIONS
can kill
LINK
460 V., 60HZ.
1. CONNECT L1 & L2 INPUT SUPPLY LINES TO INPUT SIDE
TORQUE TO 16 IN.-LBS.
OF THE TERMINAL BLOCK AS SHOWN.
L1 L2
2. CONNECT TERMINAL MARKED TO GROUND PER GND.
NATIONAL ELECTRICAL CODE.
3. REMOVE HEX NUTS AND POSITION LINKS AS SHOWN.
REPLACE AND TIGHTEN ALL HEX NUTS.
10-8-93P
M17447
THE LINCOLN ELECTRIC CO., CLEVELAND, OHIO U.S.A.
FIGURE 1- Dual Voltage
INPUT SUPPLY CONNECTION DIAGRAM LINK POSITIONS LINK
460 V.,60HZ.
FOR TRIPLE VOLTAGE MACHINE.
{
GND.
NOTE: MACHINES ARE SHIPPED FROM FACTORY CONNECTED L1 L2
FOR 440 (OR 460) VOLTS
USE FERRULE
#10 AWG ONLY
LINK POSITIONS
LINK
230 V.,60HZ.
GND.
{
L1 L2
HIGH VOLTAGE
can kill
LINK POSITIONS
1. CONNECT L1 & L2 INPUT SUPPLY LINES TO INPUT SIDE LINK
208 V.,60HZ.
OF THE TERMINAL BLOCK AS SHOWN. TORQUE TO 16 IN.-LBS.
GND.
{
L1 L2
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.
7-26-91C
M15698
THE LINCOLN ELECTRIC CO., CLEVELAND, OHIO U.S.A.
FIGURE 1- Triple Voltage
� 23 � May96
Do not operate with covers removed
CUTTING TORCH CONNECTION DIAGRAM
Disconnect input power before servicing
TM
FOR MAGNUM PCT 60 Do not touch electrically live parts
Only qualified persons should install,
PLASMA TORCH use or service this equipment
AMPHENOL
1. DISCONNECT INPUT POWER TO THE PRO-CUT
ADAPTER
CONNECTOR
AND TURN MACHINE POWER SWITCH OFF.
GAS LINE
2. INSERT TORCH CABLE THROUGH CABLE BOOT.
PILOT
TURN AND LOCK STRAIN RELIEF CLAMP ONTO
STRAIN RELIEF CLAMP LEAD
BOLT.
3. CONNECT PILOT LEAD.
PILOT
4. PLACE GAS LINE FITTING ON ADAPTER AND
BOLT
SCREW TIGHT.
CABLE BOOT
5. ATTACH AMPHENOL CONNECTOR.
WORK
WORK LEAD
PRO-CUT 60 POWER SOURCE
7-26-91C
THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A. S19941
FIGURE 2
� 24 �
May96
NOTES
LINCOLN ELECTRIC SERVICE MANUALS
Now Available ...The following Service Manuals
These are comprehensive single sources of information relative to Installation, Operation,
Maintenance, Accessories, Theory of Operation, Replacement Parts, Electrical Diagrams and
Extensive Troubleshooting.
ORDER FROM: Technical Service Group-Customer Service Dept.
Lincoln Electric Company
22801 St. Clair Ave.
Cleveland, Ohio 44117-1199
All orders must be pre-paid (US Funds Only): Please allow up to 4 weeks for delivery.
Make checks or Money Orders payable to the Lincoln Electric Company
Qty. Titles Machine Codes Manual # Unit Price Total Price
Square Wave Tig 255 (Codes 10022-10134) SVM100-A $45.00
V300I (Codes 9826-10133) SVM101-A $45.00
SP100 (Codes 9284-10050) SVM102-A $45.00
Power Arc 4000 (Codes 10083) SVM103-A $45.00
Power Arc 4000 (Codes 10200-10244) SVM103-B $45.00
ProCut 60 Single Phase (Codes 9819-10118) SVM104-A $45.00
V300 PRO (Codes 9934-10131) SVM105-A $45.00
LN 7 GMA (Codes 9168-9931) SVM106-A $45.00
RANGER 8 (Codes 9972-10110) SVM107-A $45.00
DC600 (Codes 9773-9910) SVM108-A $45.00
POWER WAVE 350/500 (Codes 10104-10155) SVM109-A $65.00
RANGER 9 (Codes 9975-9976) SVM110-A $45.00
SP250 (Codes 9402-10002) SVM111-A $45.00
POWER WAVE 450 (Codes 10105-10195) SVM112-A $65.00
WELDAN POWER 125 (Codes 10158-10160) SVM113-A $45.00
LN25 (Codes 9218-10150) SVM114-A $45.00
SP255 (Codes 10164-10165) SVM115-A $45.00
Idealarc CV-300 (Codes 9456-10181) SVM116-A $45.00
Wire-matic 250 (Codes 9799-10004) SVM117-A $45.00
Square Wave TIG 355 (Codes 9951-9955) SVM118-A $45.00
Wire-matic 255 (Codes 10166,10167) SVM119-A $45.00
Ranger 10-LX (Codes 9975, 9976) SVM120-A $45.00
TOTAL
SHIP MANUALS TO:
Name:
Address:
Phone:
SD-267 3/96
Now Available...12th Edition New Lessons in Arc Welding
The Procedure Handbook of Arc Welding Lessons, simply written, cover manipulatory techniques;
With over 500,000 copies of previous editions published machine and electrode characteristics; related subjects,
since 1933, the Procedure Handbook is considered by many to such as distortion; and supplemental information on arc
be the “Bible� of the arc welding industry. welding applications, speeds and costs. Practice materials,
exercises, questions and answers are suggested for each
This printing will go fast so don’t delay. Place your
lesson.
order now using the coupon below.
528 pages, well illustrated, 6� x 9� size, bound in simulated,
The hardbound book contains over 750 pages of welding
gold embossed leather.
information, techniques and procedures. Much of this material
$5.00 postage paid U.S.A. Mainland
has never been included in any other book.
A must for all welders, supervisors, engineers and
designers. Many welding instructors will want to use the book
as a reference for all students by taking advantage of the low
quantity discount prices which include shipping by
4th class parcel post.
$15.00 postage paid U.S.A. Mainland
Need Welding Training?
The Lincoln Electric Company operates the oldest and
most respected Arc Welding School in the United States at its
How To Read Shop Drawings
corporate headquarters in Cleveland, Ohio. Over 100,000 stu-
dents have graduated. Tuition is low and the training is
The book contains the latest information and application
“hands on�
data on the American Welding Society Standard Welding
For details write: Lincoln Welding School
Symbols. Detailed discussion tells how engineers and
22801 St. Clair Ave.
draftsmen use the “short-cut� language of symbols to pass
on assembly and welding information to shop personnel. Cleveland, Ohio 44117-1199.
Practical exercises and examples develop the reader’s ability and ask for bulletin ED-80 or call 216-383-2259 and ask for the
to visualize mechanically drawn objects as they will appear Welding School Registrar.
in their assembled form.
187 pages with more than 100 illustrations. Size 8-1/2� x 11� Lincoln Welding School
Durable, cloth-covered board binding. BASIC COURSE $700.00
$4.50 postage paid U.S.A. Mainland 5 weeks of fundamentals
There is a 10% discount on all orders of $50.00 or more for shipment at one time to one location.
Orders of $50 or less before discount or orders outside of North America must be prepaid with charge, check or money order in U.S. Funds Only.
Prices include shipment by 4 th Class Book Rate for U.S.A. Mainland Only. Please allow up to 4 weeks for delivery.
UPS Shipping for North America Only. All prepaid orders that request UPS shipment please add:
$5.00 For order value up to $49.99
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$15.00 For order value between $100.00 & $149.00
For North America invoiced orders over $50.00 & credit card orders, if UPS is requested, it will be invoiced or charged to you at cost.
Outside U.S.A. Mainland order must be prepaid in U.S. Funds. Please add $2.00 per book for surface mail or $15.00 per book for air parcel post shipment.
METHOD OF PAYMENT: (Sorry, No C.O.D. Orders) Name: _______________________________________________
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USE THIS FORM TO ORDER: Order from: BOOK DIVISION, The Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199
Telephone: 216-383-2211 or, for fastest service, FAX this completed form to: 216-361-5901.
BOOKS OR FREE INFORMATIVE CATALOGS
Ë
Lincoln Welding School Titles: Price Code Quantity Cost
(ED-80) New Lessons in Arc Welding $5.00 L
Ë
Seminar Information Procedure Handbook “Twelfth Edition� $15.00 PH
(ED-45) How to Read Shop Drawings $4.50 H
Ë
Educational Video Information Incentive Management $5.00 IM
(ED-93) A New Approach to Industrial Economics $5.00 NA
James F. Lincoln Arc Welding The American Century of John C. Lincoln $5.00 AC
Ë
Foundation Book Information Welding Preheat Calculator $3.00 WC-8
(JFLF-515) Pipe Welding Charts $4.50 ED-89
SUB TOTAL
Additional Shipping Costs if any
TOTAL COST
q Do not touch electrically live parts or q Keep flammable materials away. q Wear eye, ear and body protection.
WARNING electrode with skin or wet clothing.
q Insulate yourself from work and
ground.
Spanish
q No toque las partes o los electrodos q Mantenga el material combustible q Protéjase los ojos, los oÃdos y el
AVISO DE bajo carga con la piel o ropa moja- fuera del área de trabajo. cuerpo.
da.
PRECAUCION q Aislese del trabajo y de la tierra.
French q Ne laissez ni la peau ni des vête- q Gardez à l’écart de tout matériel q Protégez vos yeux, vos oreilles et
ments mouillés entrer en contact inflammable. votre corps.
ATTENTION avec des pièces sous tension.
q Isolez-vous du travail et de la terre.
German q Berühren Sie keine stromführenden q Entfernen Sie brennbarres Material! q Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
WARNUNG Körper oder feuchter Kleidung!
q Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese
q Não toque partes elétricas e elec- q Mantenha inflamáveis bem guarda- q Use proteção para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
ATENÇÃO da.
q Isole-se da peça e terra.
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-
STELLERS. DIE UNFALLVERHÃœTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
q Keep your head out of fumes. q Turn power off before servicing. q Do not operate with panel open or
WARNING
q Use ventilation or exhaust to guards off.
remove fumes from breathing zone.
Spanish
q Los humos fuera de la zona de res- q Desconectar el cable de ali- q No operar con panel abierto o
AVISO DE
piración. mentación de poder de la máquina guardas quitadas.
q Mantenga la cabeza fuera de los antes de iniciar cualquier servicio.
PRECAUCION
humos. Utilice ventilación o
aspiración para gases.
French
q Débranchez le courant avant l’entre- q N’opérez pas avec les panneaux
q Gardez la tête à l’écart des fumées.
tien. ouverts ou avec les dispositifs de
q Utilisez un ventilateur ou un aspira-
ED
ATTENTION
protection enlevés.
teur pour ôter les fumées des zones
de travail.
1 SED
German
q Strom vor Wartungsarbeiten q Anlage nie ohne Schutzgehäuse
q Vermeiden Sie das Einatmen von
abschalten! (Netzstrom völlig öff- oder Innenschutzverkleidung in
Schweibrauch!
WARNUNG
nen; Maschine anhalten!) Betrieb setzen!
q Sorgen Sie für gute Be- und
W ER
Entlüftung des Arbeitsplatzes!
IM P Portuguese
q Não opere com as tampas removidas. q Mantenha-se afastado das partes
q Mantenha seu rosto da fumaça.
E SU
q Desligue a corrente antes de fazer moventes.
q Use ventilação e exhaustão para
ATENÇÃO
S
serviço. q Não opere com os paineis abertos
remover fumo da zona respiratória.
q Não toque as partes elétricas nuas. ou guardas removidas.
SE Y
Japanese
NT
RA
Chinese
AR
W
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÃTICAS DE SEGURANÇA DO EMPREGADOR.
|