RETURN TO MAIN MENU IM10006 PLASMA 20 For use with machines having Code Number: June, 2009 11578 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 READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly, think before you act and be careful.
i i SAFETY WARNING PLASMA CUTTING or GOUGING can be hazardous. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING. Read and understand the following safety highlights. For additional safety information it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.
ii ii SAFETY 4.c. When not cutting or gouging, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard. FOR ELECTRICALLY powered equipment. 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. They can cause an explosion even though they have been “cleaned.
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iv iv SAFETY 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 suivantes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits à l’électrode et à la piéce sont sous tension quand la machine à souder est en marche.
v v Thank You 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! CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations.
vi TABLE OF CONTENTS Page Installation.......................................................................................................................Section A Technical Specifications .......................................................................................................A-1 Safety Precautions ...............................................................................................................A-2 Select Proper Location .......................................................
A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - PLASMA 20 INPUT - SINGLE PHASE Standard Voltage 1Ø Input Current at Rated Output 115/1/50/60Hz (15 Amp Branch) 115/1/50/60Hz (20 Amp Branch with 20 Amp Plug*) 115 V: 20A @ 50% 115 V: 26A @ 40% RATED OUTPUT Duty Cycle AMPS 50% on 115V (15 Amp Branch) 40% on 115V (20 Amp Branch with 20 Amp Plug*) 15 A 20 A OUTPUT Open Circuit Voltage 310 VDC Current Range 10-20 Amps REQUIRED AIR FLOW RATE Pilot Current 17 Amps REQUIRED AIR INLET PRESSURE 72.
A-2 A-2 INSTALLATION Read entire Installation Section before installing the PLASMA 20. SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK CAN KILL. • Only qualified personnel should perform this installation. • Only personnel that have read and understood the PLASMA 20 Operating Manual should install and operate this equipment. • Machine must be plugged into a receptacle which is grounded per any national, local or other applicable electrical codes.
A-3 A-3 INSTALLATION Use of normal 20 amp household breakers may result in over current trips. If breaker trips occur, reduce the cutting current output until nuisance trips stop. WARNING CYLINDER could explode if damaged. COMPRESSED AIR OR GAS INPUT CONNECTION A source of clean, dry air or nitrogen must be supplied to the PLASMA 20. Oil in the air is a severe problem and must be avoided. The supply pressure must be between 72.5 and 150 psi (5 and 10.3 bar). The flow rate is approximately 3.5 cu. ft.
B-1 OPERATION B-1 DESCRIPTION SAFETY PRECAUTIONS WARNING The PLASMA 20 is a constant current, continuous control plasma cutter power source. ELECTRIC SHOCK can kill. The PLASMA 20 comes standard with an air regulator and pressure gauge. The unit is powered from a 115Vac, 20 amp input circuit with a 40% duty cycle rating on a 10 minute basis, with 20 amp output. The unit includes a hand-held torch with consumables and a work cable with clamp.
B-2 B-2 OPERATION USER RESPONSIBILITY CONTROLS AND SETTINGS 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 individual conditions. Test all procedures duplicating actual field conditions.
B-3 OPERATION B-3 CUTTING OPERATIONS CHECKING AIR QUALITY BEFORE CUTTING To check air quality, deactivate the torch (post-flow) and place a welding filter lens in front of the torch. Any oil or moisture in the air will be visible on the lens. DO NOT initiate pilot arc while checking air quality. WARNING ELECTRIC SHOCK CAN KILL. Disconnect input power by removing the plug from the receptacle before assembling or disassembling torch parts, or torch and lead assemblies.
B-4 B-4 OPERATION • 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 3 seconds and the pilot arc will start. - The pilot arc will run for 3.0 seconds and shut off unless the arc is brought in contact with the work and the arc is transferred. Avoid excessive pilot arc time by transferring the arc to the workpiece quickly.
B-5 B-5 OPERATION PILOT ARC DISCUSSION FIGURE B.2 The PLASMA 20 has a smooth, continuous pilot arc. The pilot arc is only a means of transferring the arc to the workpiece for cutting. Repeated pilot arc starts, in rapid succession, is not recommended as these starts will generally reduce consumable life. Occasionally, the pilot arc may sputter or start intermittently. This is aggravated when the consumables are worn or the air pressure is too high.
D-1 MAINTENANCE D-1 PERIODIC MAINTENANCE WARNING WARNING ELECTRIC SHOCK can kill. • Have an qualified person service this equipment. • Disconnect input power by removing plug from receptacle before assembling or disassembling torch parts, or torch and lead assemblies. • Do not touch electrically hot parts. ---------------------------------------------------------------------- ELECTRIC SHOCK CAN KILL.
D-2 MAINTENANCE COMPRESSED AIR FILTER The unit is supplied with a filter for the compressed air and fitted with a manual drain for condensation. (Drain is located on the bottom of the filter). Purge periodically to remove the water in the filter by opening the drain knob. Do not use solvents to clean the filter; use soapy water only.
E-1 TROUBLESHOOTING E-1 HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
E-2 E-2 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) GREEN LED OFF, Fan not operating. No Input Power. POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION 1. Plug unit into 115V outlet. 2. Reset Breaker. GREEN LED ON, YELLOW Overtemperature / under pressure LED ON. Unit is overheated. 1. Make sure the unit has not been operated beyond duty cycle limits. 2. Air Flow obstructed. GREEN LED ON, YELLOW Over temperature / under pressure LED blinks.
CONTROL BOARD INVERTER BOARD 11/ 07 DIAGRAMS PLASMA 20 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.
NOTES PLASMA 20
● Do not touch electrically live parts or WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO ● Keep flammable materials away. ● Wear eye, ear and body protection. ● Mantenga el material combustible ● Protéjase los ojos, los oídos y el electrode with skin or wet clothing. ● Insulate yourself from work and ground. ● No toque las partes o los electrodos bajo carga con la piel o ropa mojada. ● Aislese del trabajo y de la tierra.
● Keep your head out of fumes. ● Use ventilation or exhaust to ● Turn power off before servicing. ● Do not operate with panel open or guards off. remove fumes from breathing zone. ● Los humos fuera de la zona de res- piración. ● Mantenga la cabeza fuera de los humos. Utilice ventilación o aspiración para gases. ● Gardez la tête à l’écart des fumées. ● Utilisez un ventilateur ou un aspira- ● Desconectar el cable de ali- mentación de poder de la máquina antes de iniciar cualquier servicio.
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