RETURN TO MAIN MENU IM595-A PRO-CUTTM 80 For use with machines having Code Numbers: May, 2004 10573, 10574, 10575, 10576, 10577, 10578 11019, 11020, 11021, 11022, 11023, 11024 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.
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.
NOTES
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 vi TABLE OF CONTENTS Page Installation.......................................................................................................................Section A Technical Specifications .......................................................................................................A-1 Safety Precautions ...............................................................................................................A-2 Select Proper Location ...................................................
vii vii TABLE OF CONTENTS Page Maintenance ....................................................................................................Section D Safety Precautions ................................................................................................D-1 Input Filter Capacitor Discharge Procedure ..........................................................D-1 Routine Maintenance.............................................................................................
A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - PRO-CUT 80 INPUT THREE PHASE Standard Voltage 208/230/460 200/380-415 460/575 SINGLE PHASE Input Current at Rated Output 48/44/25 46/27/24 25/20 Standard Voltage 208/230/460 Model 50/60 Hz 50/60 Hz 50/60 Hz Input Current at Rated Output 87/81/48 Model 50/60Hz RATED OUTPUT Duty Cycle AMPS VOLTS 60% Duty Cycle 100% Duty Cycle 80 60 140 130 OUTPUT Current Range Open Circuit Voltage Pilot Current MAX 335 VDC 20 Amps @ 100% Duty Cycle 35-85 Amp
A-2 INSTALLATION Read entire Installation Section before installing the PRO-CUT 80. 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 A-3 INSTALLATION CORD REMOVAL: INPUT ELECTRICAL CONNECTIONS 1. Unplug line cord from the receptacle. 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 80 should be connected only by a qualified electrician. Installation should be made in accordance with all local and national codes (eg: U.S.
A-4 A-4 INSTALLATION For 380 - 415 VAC Supplies: FRAME GROUNDING The frame of the Pro-Cut 80 must be properly grounded. A ground terminal marked is mounted on the case bottom directly behind the input power switch for this purpose. The cable that is sent attached to the machine is connected to this ground terminal. See the National Electric Code for details on proper grounding methods. Install in accordance with all local and national electrical codes.
A-5 A-5 INSTALLATION GAS INPUT CONNECTIONS Supply the PRO-CUT 80 with clean compressed air or nitrogen. • Supply pressure must be between 80 psi(5.6kg/cm2) and 120 psi(8.4kg/cm2). • Pressure gage, located on the front of the machine, should be set to approximately 70 psi(4.9kg/cm2) for a 25ft.(7.6m) torch and 75 psi(5.3kg/cm2) for a 50 ft.(15.2m) torch while gas is flowing (purging or cutting). • Flow rate should be approximately 8.0 cfm (227 I/min.).
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 80 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 80 is rated at 80 amps, at 60% duty cycle on a 10 minute basis (runs 80 amps for 6 minutes, then idling for 4 minutes) or 60 amps, at 100% duty cycle (continuous use). 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. Recommended Torch Travel Speed (IPM)(mm/m) 80% of Maximum Speed Figure B.1 shows the cut capacity of the PRO-CUT 80 when cutting mild steel.
B-4 B-4 OPERATION LIMITATIONS Do not exceed the output current and duty cycle rating of machine. Do not use the PRO-CUT 80 for pipe thawing. GAS PRESSURE SETTINGS CONTROLS AND SETTINGS Status Indicators Reset Button XXXX XXXX XXXX Gas Purge Button Gas Regulator Gauge XXXX Gas Regulator Knob Output Control Knob • Push-in and hold the Purge button to check or set the gas pressure. Pull the pressure regulator cap out and turn it to set the pressure. - Adjust the gas regulator for 70psi(4.
B-5 B-5 OPERATION ANGLE OF APPROACH • Hold the nozzle standoff 1/8” (3.2mm) to 3/16” (4.8mm) above the workpiece during cutting. Do not let the nozzle touch the work or carry a long arc. Gloves Required TORCH HELD AT 0 45 ANGLE THROUGHOUT GOUGE • 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 B-7 OPERATION Suggestions for Extra Utility from the PRO-CUT System: h. 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. 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.
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 80. • 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 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. • Prior to Performing preventative maintenance, perform the following capacitor discharge procedure to avoid electric shock. --------------------------------------------------------------------- 4. Obtain a high resistance and high wattage resistor (25-1000 ohms and 25 watts minimum).
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 MISADJUSTMENT(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 MISADJUSTMENT(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 MISADJUSTMENT(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, at least 3 seconds. and are in good shape. Replace the consumables if necessary. 2. Make sure the air pressure is set at 70 psi (75 psi for a 50 ft. torch). 3.
E-5 E-5 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(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.
E-7 E-7 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENTS(S) RECOMMENDED COURSE OF ACTION CONSUMABLE RELATED SAFETY LED If the Safety LED is LIT AND STEADY, perform the following: Press the reset button. If the torch 1. If the reset button (when pressed) and consumables are properly does not turn the Safety LED off, installed, the Safety LED should turn the reset button or associated off. wiring may be faulty.
206 207A 202 S4 PRIMARY RECONNECT 203 FAN FAN MOTOR 460V A 202 XFER B21 OUTPUT X2 X4 - 207 C2 3000/450 + POWER L1 401 S 2 2 3 4 6 7 8 6 7 1 2 3 13 14 4 5 6 E 5 3 12 2 4 9 10 11 1 1 5 8 343 344 5 361 310 348 347 53 56 51 312 303 354 54 E 360 2 4 404 507 506 505 4A 309 2A 365 364 3 4 8 369 366 9 2 7 W R W R 503 502 501 10 1 6 X20 X40 1 3 4 J33 12V CHOKE J30 1,4 24V J32 8 AIR SOL 2 ELEC SOL 3 TRIGGER 13 IGBT 14 GND J34
PRO-CUT 55 241 248 208 201A 231A 201 238 S4 PRIMARY RECONNECT FAN 231 A 241 202 X4 XFER B21 OUTPUT X2 201 - 207 C2 2000/500 + POWER L1 401 S J11 4 3 2 4 E 1 3 7 14 6 6 13 2 5 12 5 4 11 4 3 10 344 4 8 1 3 7 2 2 8 1 5 6 9 343 5 310 53 54 56 51 312 303 354 309 348 347 361 E 360 2 4 365 4A 2A 364 10 369 3 4 2 R W 8 7 R W 238 201A 366 204 404 507 506 505 231A 503 502 501 9 1 6 X20 X40 1 2 1 3 J33 12V C
FAN PRO-CUT 55 H4 H5 440460V 220230V H3 A 202 X2 X4 B21 L1 CHOKE X40 X20 J33 ELEC 3 1 XFER 4 2 R W R W 404 S 401 E 6 1 360 J37 1 NOZZLE 7 2 3,8 WORK 8 3 365 5,10 ELECTRODE 343 9 4 E 10 5 344 5 1 J36 G 2,3 = 24V 6 2 54 4,8 = OK TO MOVE 7 3 51 8 4 347 348 4 7 1 2 J38 8 2 1,7 TRIGGER 361 9 3 3,4 AIR SOL 10 366 4 5,6 ELEC SOL 56 11 5 11,12 = 12V 369 53 12 6 364 3 1 J39 2,4 TRIGGER 4 2 4A 2A J35 4 1 309 1 AIR SOL 303 310 2 ELEC SOL 5 2 312 3 TRIGGER 354 4 IGBT 6 GND 6 3 XFER C2 3000/450 + -
PRO-CUT 55 FAN 201A 201 231A 208 231 H5 A H6 550575V 0.
16.41 13.71 3.50 DIMENSION PRINT PRO-CUT 80 22.50 29.
NOTES PRO-CUT 80
WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO ● Do not touch electrically live parts or ● 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.
• World's Leader in Welding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.