RETURN TO MAIN MENU TOMAHAWK ™ 1000 For use with machines having Code Number: IM10026 September, 2012 11581 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.
i SAFETY WARNING i 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. 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 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 LʼArc 1. Protegez-vous contre la secousse électrique: a. Les circuits à lʼélectrode et à la piéce sont sous tension quand la machine à souder est en marche.
v Thank You v 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 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 -TOMAHAWK™ 1000 INPUT - SINGLE PHASE/THREE PHASE/ 50 / 60 HERTZ Input Voltage +/- 10% Input Amperes @ Rated Output 38 25 34 23 25 16 21 13 9 6 8 5 208V/1/50/60 230V/1/50/60 208V/3/50/60 230V/3/50/60 460V/3/50/60 575V/3/50/60 Circuit Breaker (Delay Type) 50% Duty Cycle 100% Duty Cycle 50% Duty Cycle 100% Duty Cycle 50% Duty Cycle 100% Duty Cycle 50% Duty Cycle 100% Duty Cycle 50% Duty Cycle 100% Duty Cycle 50% Duty Cycle 100% Duty Cycle 40 Amps 30 Amps
A-2 A-2 INSTALLATION Read entire Installation Section before installing the TOMAHAWK™ 1000 . 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 equipment. • Do not touch electrically hot parts. • Turn the TOMAHAWK™ 1000 Power Switch OFF when connecting power cord to input power.
A-3 A-3 INSTALLATION Attachment plugs must comply with the Standard for Attachment Plugs and Receptacles, UL498. The product is considered acceptable for use only when an attachment plug as specified is properly attached to the supply cord. ENGINE DRIVEN GENERATOR For use on engine drives, keep in mind the above input draw restrictions and the following precaution.
B-1 OPERATION B-1 DESCRIPTION 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. The TOMAHAWK™ 1000 is a constant current, continuous control plasma cutting power source. It provides superior and reliable starting characteristics, cutting visibility and arc stability.
B-2 OPERATION USER RESPONSIBILITY Because design, fabrication, erection and cutting variables affect the results obtained in applying this type of information, the serviceability of a product or structure 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.
B-3 B-3 OPERATION CUTTING CAPABILITY CONSUMABLE LIFE The TOMAHAWK™ 1000 is rated at 60 amps, at 50% 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. The expected life for the TOMAHAWK™ 1000 's electrode under normal operating conditions is approximately 1000 starts/cuts. An erosion of .060" is typical for end of electrode life, however, the electrode life may last longer.
B-4 B-4 OPERATION LIMITATIONS 3. Output red LED: The cutting torch is energized. Do not exceed output current and duty cycle rating of machine. Do not use the TOMAHAWK™ 1000 for pipe thawing. CONTROLS AND SETTINGS (Figure B.2) TOMAHAWK™ 1000 front command panel. FIGURE B.2 2 8 3 4 5 7 6 1 When the machine is turned ON, an auto-test is executed; during this test all of the LEDs on the Control Panel light up. 1. Output Current Knob: For setting the output current used during cutting.
B-5 B-5 OPERATION 7. Primary Air, Gas Pressure Gauge and Regulator Knob: Allows the regulation and monitoring of the primary air/gas pressure. The inlet primary air/gas pressure is limited by this pressure regulator, set at the factory to 80 PSI (5.5 bar). To adjust the air/gas pressure, place the machine in Purge mode. 1MPa = 145 psi WARNING Clean, dry air or gas must be supplied to the machine. A pressure setting above 110 PSI (7.5 bar) could damage the torch.
B-6 B-6 OPERATION • The Post Flow time is proportional to the selected cutting current and it is divided into 4 time ranges: Selected Cutting Current 15 seconds 20 seconds 25 seconds 30 seconds • Pilot Arc - 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, the initial trigger will be ignored. This is a safety feature to prevent the pilot arc from firing unexpectedly.
B-7 B-7 OPERATION Applications: PILOT ARC DISCUSSION Removing weld imperfections – cracks, porosity, inclusions, etc. Back gouging for welding preparation Removal of temporary fit up methods – tack welds, bracketing, etc. The TOMAHAWK™ 1000 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.
B-8 OPERATION • Where possible, start the cut from the edge of the work piece. • Keep moving! A steady speed is necessary. Do not pause. Suggestions for Extra Utility from the TOMAHAWK™ 1000 System: B-8 • Set air pressure to recommended setting. A higher or lower pressure will cause turbulence in the plasma arc, eroding the orifice of the nozzle tip. • Use only Lincoln consumable parts.
B-9 OPERATION B-9 TORCH PART CONFIGURATIONS Different hand held torch configurations are available 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. The advantage of this cutting method is good visibility of the arc. However it requires a steady hand to avoid touching the nozzle to the work piece which will cause premature nozzle wear and a jagged cut.
B-10 OPERATION B-10 GOUGING SETUP: If gouging metal and not cutting completely through the part is required, a special gouging nozzle is used in conjunction with a gouge shield to protect the nozzle from molten metal blow back. 3-10 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.
B-11 OPERATION MACHINE INTERFACE The TOMAHAWK™ 1000 comes standard with a machine interface. Interface signals provided include: arc start, arc initiated, and arc voltage. These signals are accessible through the 14 pin connector on the case front. ARC START: The Arc Start circuit allows for triggering of the power source to commence cutting. This circuit can be accessed through pins K and M of the 14 pin connector.
C-1 ACCESSORIES GENERAL OPTIONS /ACCESSORIES The following options/accessories are available for your Tomahawk™ Plasma cutter from your local Lincoln Distributor. K2886-1 - Plasma Circle Cutting Kit - For cutting circles from 3” to 33” in diameter (77mm to 838mm). TORCHES The following replacement or optional torches are available: K2848-1 LC65 Handheld Plasma Torch 25' (7.5m) K2848-2 LC65 Handheld Plasma Torch 50' (15m) K2848-3 LC65M Mechanized Plasma Torch 25' (7.
D-1 D-1 MAINTENANCE PERIODIC MAINTENANCE WARNING ELECTRIC SHOCK CAN KILL. • Have an electrician install and service 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.
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) POSSIBLE AREAS OF MISADJUSTMENTS RECOMMENDED COURSE OF ACTION Input circuit breaker trips repeatedly. 1. This may be normal. If output is set to maximum a 30 amp circuit is required. See Technical Specification page. 2. Install a larger input circuit or turn the output control to a lower amperage. No Status indicators light and the fan 1.
E-3 E-3 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENTS RECOMMENDED COURSE OF ACTION The TOMAHAWK™ 1000 powers 1. Turn the output knob to purge up properly but there is no response zone on the front of the TOMAwhen the trigger is pulled and only HAWK™ 1000 . If air does not the POWER LED is lit. flow, then: • The main gas solenoid assembly/pressure sensor may be faulty. Check or replace. • Possible faulty Control board.
E-4 E-4 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENTS RECOMMENDED COURSE OF ACTION When the trigger is pulled air begins 1. Check the torch consumables to be to flow, but there is no pilot arc after sure they are not dirty or greasy, at least 3 seconds. and are in good shape. Replace the consumables if necessary. 2. Make sure the air pressure is set correctly. 3.
E-5 E-5 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENTS RECOMMENDED COURSE OF ACTION Pilot arc starts but will not transfer 1. Check work lead connection for when brought near work. clean, secure connection. 2. Plasma will only cut conductive material. Do not attempt to cut fiberglass, plastic, rubber, PVC or any other non-conductive material. If all recommended possible areas of misadjustment have been checked 3.
E-6 E-6 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual SYMPTOM STATUS BOARD INDICATORS CHECK Yellow Gas Pressure LED is lit and steady. 1. Make sure there is at least 80 psi connected to the gas connection at the back of the machine. 2. Turn the output knob to the purge zone and set the regulator to the correct pressure. The pressure may increase when air stops flowing but this is normal. Do not reset the pressure while the air is OFF. 3. Possible faulty Pressure Switch.
E-7 TROUBLESHOOTING E-7 Observe all Safety Guidelines detailed throughout this manual Error condition list V On (Green LED) No pilot arc established On (Yellow LED) On (Yellow LED) 1. The Torch Trigger pushbutton is pressed. During this period the machine will attempt to start the pilot arc for 4 times. If the pilot arc does not start, the machine automatically will enter into a safe status condition that will allow troubleshooting as necessary. 2.
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.
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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