RETURN TO MAIN MENU PRO-CUTTM 55 For use with machines having Code Numbers: IM590 December, 2002 10473, 10474, 10475 and 10476 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 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.g. Sparks and spatter are thrown from the plasma arc. Wear safety glasses, ear protection and oil free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs when cutting or gouging out of position or in confined places. Always wear safety glasses with side shields when in a cutting or gouging area. 4.h. Connect the work cable to the work as close to the cutting or gouging area as practical.
iii NOTES iii
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! Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped, title passes to the purchaser upon receipt by the carrier.
vi TABLE OF CONTENTS Page Installation.......................................................................................................................Section A Technical Specifications .......................................................................................................A-1 Safety Precautions ...............................................................................................................A-2 Select Proper Location .......................................................
vii TABLE OF CONTENTS Page Maintenance ....................................................................................................Section D Safety Precautions ................................................................................................D-1 Input Filter Capacitor Discharge Procedure ..........................................................D-1 Routine Maintenance.............................................................................................D-2 Periodic Maintenance .
A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - PRO-CUT 55 INPUT - SINGLE or THREE PHASE / 60 HERTZ ONLY Standard Voltage 1Ø Input Current at Rated Output 3Ø Input Current at Rated Output 230/460/1 or 3Ø/60 Hz 230V: 55A @ 50%, 40A @ 100% 460V: 30A @ 50%, 23A @ 100% 230V: 28A @ 50%, 21A @ 100% 460V: 17A @ 50%, 15A @ 100% Idle Current: 0.
A-2 INSTALLATION Read entire Installation Section before installing the PRO-CUT 55. A-2 LIFTING AND MOVING Either the front or rear handles or both may be used to lift or move the machine. 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.
A-3 INSTALLATION A-3 INPUT ELECTRICAL CONNECTIONS INPUT POWER CORD CONNECTOR INSTALLATION Before installing the machine, check that input supply voltage, phase, and frequency are the same as the machine's voltage, phase, and frequency as specified on the machine's rating plate. The Pro-Cut 55 is supplied with one 11' #8 AWG 3 lead input power cord already connected to the machine. A cord connector provides a strain relief for the input power cord as it passes through the left rear access hole.
A-4 GAS INPUT CONNECTIONS Supply the PRO-CUT 55 with clean compressed air or nitrogen. • • Supply pressure must be between 80 psi and 150 psi. Flow rate should be approximately 6.0 cfm (170 I/min.). NOTE: Oil in the air supply to the PRO-CUT 55 can cause severe problems. Use only a clean air supply. • • A-4 INSTALLATION Connect the gas supply to the PRO-CUT 55 regulator. Compressed gas should be supplied to the fitting connection mounted on the filter at the rear of the machine.
B-1 OPERATION Read and understand this entire section before operating the machine. 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. B-1 DESCRIPTION The Pro-Cut 55 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 - Input over voltage protection. 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 The PRO-CUT 55 is rated at 55 amps, at 50% duty cycle on a 10 minute basis or 40 amps, at 100% duty cycle. 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. Figure B.1 shows the cut capacity of the Pro-Cut 55 when cutting mild steel. The graph plots cut thickness vs. torch travel speed with a torch standoff of 0.15". Example: 0.
B-4 B-4 OPERATION kerf (cut) width, heat affected zone or travel speed as required. LIMITATIONS Do not exceed output current and duty cycle rating of machine. Do not use the PRO-CUT 55 for pipe thawing.
B-5 B-5 OPERATION ANGLE OF APPROACH • Hold the nozzle standoff 1/8” (3.2mm) to 3/16” (4.7mm) above the workpiece during cutting. Do not let the torch nozzle touch the work or carry a long arc. • Keep moving while cutting. Cut at a steady speed without pausing. Maintain the cutting speed so that the arc leg is 10° to 20° behind the travel direction.
B-6 B-6 OPERATION Thick Sections of Metal PILOT ARC DISCUSSION The PRO-CUT 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.
B-7 OPERATION Suggestions for Extra Utility from the PRO-CUT System: WARNING ELECTRIC SHOCK CAN KILL. • Turn off machine at the disconnect switch on the front of the machine before tightening, cleaning or replacing consumables. ---------------------------------------------------------------------------1. Occasionally an oxide layer may form over the tip of the electrode, creating an insulating barrier between the electrode and nozzle. This will result in the tripping of the Pro-Cut's safety circuit.
C-1 ACCESSORIES ALWAYS USE GENUINE LINCOLN ELECTRIC ELECTRODES AND VORTECH™ NOZZLES • Only Genuine Lincoln Electric consumables yield the best cutting performance for the PRO-CUT 55. • The patented VORTECH™ nozzle provides an extra “kick” of swirl as the arc exits the nozzle which improves cutting performance. No other nozzle has this capability or can match its performance.
D-1 D-1 MAINTENANCE 4. Obtain a high resistance and high wattage resistor (25-1000 ohms and 25 watts minimum). This resistor is not supplied with machine. NEVER USE A SHORTING STRAP FOR THIS PROCEDURE. 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.
D-2 D-2 MAINTENANCE ROUTINE MAINTENANCE PERIODIC MAINTENANCE 1. Keep the cutting or gouging area and the area around the machine clean and free of combustible materials. No debris should be allowed to collect which could obstruct air flow to the machine. 2. Every 6 months or so, the machine should be cleaned with a low pressure airstream. Keeping the machine clean will result in cooler operation and higher reliability.
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(S) RECOMMENDED COURSE OF ACTION No Status indicators light and the fan 1. Check the input power to be sure does not operate 5 seconds after the it is on. power switch is turned on. 2. Check the power line fuses and machine connection. 3. Disconnect input power at fuse panel and check line switch continuity. Replace line switch if bad. 4.
E-3 E-3 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENTS(S) RECOMMENDED COURSE OF ACTION The Pro-Cut powers up properly but 1. Press Purge button on the front of there is no response when the trig- the Pro-Cut. If air does not flow, ger is pulled and only the POWER then: LED is lit. a. Auxiliary transformer may be faulty. b. The main gas solenoid assembly may be faulty. Check or replace. c.
E-4 E-4 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENTS(S) 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, and are in good shape. Replace at least 3 seconds. the consumables if necessary. 2. Make sure the air pressure is set at 70 psi. 3.
E-5 E-5 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENTS(S) 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 TROUBLESHOOTING E-6 Observe all Safety Guidelines detailed throughout this manual STATUS BOARD INDICATORS SYMPTOM CHECK Machine is unresponsive immediately after power-up. 1. There is a 4 second soft start period for pre-charging the input filter capacitors. Wait until that time is up. The Power LED will light when ready. If not, refer to the first part of this section. The Air Low LED is lit 1. Make sure there is at least 80 psi connected to the gas connection at the back of the machine. 2.
N.D. N.C. N.B. N.A.
PRO-CUT 55 FAN FAN H1 - C2 J31 XFER 1,2 TRIGGER 1 2 3 4 401 1 4 E 3 7 14 6 6 13 2 5 12 5 3 2 9 4 1 8 10 5 10 11 3 2 4 7 8 9 1 6 X20 X40 12V S CHOKE L1 1,4=24V J30 14 GND 13 IGBT 2 ELEC SOL 3 TRIGGER 8 AIR SOL J32 10 WORK J10 3 51 56 53 54 312 G 344 310 361 360 2 4 404 507 506 505 303 309 365 364 369 366 W R W R 503 502 2 5 6 501 1 4 J33 ELEC 201 3 NOZZLE 4 ELECTRODE 5,6 AIR SOL 7,8 ELEC SOL XFER B21 OUTPUT X2 X4 120
12.60 XXXX XXXX XXXX PRO-CUT 55 OFF PRO-CUT 55 11.00 XXXX 2.95 DIMENSION PRINT PRO-CUT 55 19.50 25.
NOTES PRO-CUT 55
● 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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