RETURN TO MAIN INDEX IM665 PRO-CUTTM 25 For use with machines having Code Number: January, 2001 10661 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 CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. The Above For Diesel Engines The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS.
ii ii SAFETY ARC RAYS can burn. ELECTRIC SHOCK can kill. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground.
iii iii SAFETY WELDING SPARKS can cause fire or explosion. CYLINDER may explode if damaged. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available. 6.b.
iv SAFETY iv zones où l’on pique le laitier. 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.
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. Consequently, Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received.
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 - PRO-CUT 25 (K1756-1) INPUT - SINGLE PHASE / 60 HERTZ ONLY Standard Voltage 1Ø Input Current at Rated Output 115 V : 15 A @ 20% 115 V : 26.7A@ 60% 115 V : 37.
A-2 INSTALLATION A-2 Read entire Installation Section before installing the PRO-CUT 25. HIGH FREQUENCY INTERFERENCE PROTECTION SAFETY PRECAUTIONS The PRO-CUT 25 employs a touch start mechanism for arc initiation which eliminates high frequency emissions from the machine as compared with spark gap and solid state type high frequency generators. Keep in mind, though, that these machines may be used in an environment where other high frequency generating machines are operating.
A-3 INSTALLATION securely. WARNING: Failure to wire as instructed may cause personal injury or damage to equipment. To be installed or checked by an electrician or qualified person only. 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.
A-4 INSTALLATION NOTE: When using nitrogen gas from a cylinder, the cylinder must have a pressure regulator. • Maximum psi from a nitrogen gas cylinder to the PRO-CUT 25 regulator should never exceed 150 psi. • Install a hose between the nitrogen gas cylinder regulator and the PRO-CUT 25 gas inlet WARNING . CYLINDER could explode if damaged. • Keep cylinder upright and chained to a fixed support. • Keep cylinder away from areas where it could be damaged. • Never lift machine with cylinder attached.
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. The PRO-CUT 25 is a constant current, continuous control plasma cutting power source. It provides superior and reliable starting characteristics, cutting visibility and arc stability. The control system has a safety mechanism to insure that the nozzle and electrode are in place before cutting or gouging.
B-2 OPERATION B-2 USER RESPONSIBILITY - Continuous control, 12 - 25 amps. 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 flowrate and equipment may produce results different than those expected.
B-3 OPERATION B-3 CUTTING CAPABILITY The PRO-CUT 25 is rated at 25 amps, at 35% 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. Recommended Torch Travel Speed (IPM) 80% of Maximum Speed Figure B.1 shows the cut capacity of the PRO-CUT 25 when cutting mild steel. (The graph plots cut thickness vs. torch travel speed with a torch standoff of 0.15".
B-4 B-4 OPERATION LIMITATIONS Do not exceed output current and duty cycle rating of machine. Do not use the PRO-CUT 25 for pipe thawing. CONTROLS AND SETTINGS PRESSURE REGULATOR CAP When preparing to cut, position the machine as close to the work as possible. Make sure you have all materials needed to complete the job and have taken all safety precautions. It is important to follow these operating steps each time you use the machine. • Turn the machine's ON/OFF POWER SWITCH to OFF position.
B-5 B-5 OPERATION 5° - 15° • After the problem is found, or if there is nothing apparently wrong, reset the machine by turning the power switch OFF and then ON again. (It is possible for electrical noise to trip the safety circuit on rare occasions. This should not be a regular occurrence.) Leading Angle Direction of Travel WARNING 10° - 20° Arc Lag • Use a 5° - 15° leading angle in the direction of the cut. • Finish the cut to be made and release the trigger.
B-6 OPERATION PROCEDURE RECOMMENDATIONS When properly used, plasma arc cutting is a very economical process. Improper use will result in a very high operating cost. General - In All Cases • Follow safety precautions as printed throughout this operating manual and on the machine. • If piercing is required, slowly lower the torch at an angle of about 30° to blow the dross away from the torch tip and slowly rotate the torch to a vertical position as the arc becomes deeper.
C-1 ACCESSORIES ALWAYS USE GENUINE LINCOLN ELECTRIC ELECTRODES AND VORTECH™ NOZZLES C-1 GENERAL OPTIONS / ACCESSORIES The following options/accessories are available for your PRO-CUT 25 from your local Lincoln Distributor. • Only Genuine Lincoln Electric consumables yield the best cutting performance for the PRO-CUT 25. • The patented VORTECH™ nozzle provides an extra “kick” of swirl as the arc exits the nozzle which improves cutting performance.
D-1 MAINTENANCE D-1 THERMAL PROTECTION 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. --------------------------------------------------------------------- ROUTINE MAINTENANCE 1.
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) Input circuit breaker trips repeated. POSSIBLE AREAS OF MISADJUSTMENTS(S) RECOMMENDED COURSE OF ACTION 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(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. Reconnect Board may be faulty. b. The main gas solenoid assembly may be faulty. Check or replace. c. Possible faulty Control board. 2.
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, at least 3 seconds. and are in good shape. Replace the consumables if necessary. 2. Make sure the air pressure is set at 65 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 The Air Low LED is lit CHECK 1. Make sure there is at least 80 psi connected to the gas connection at the back of the machine. 2. Press the Purge button and set the regulator to 55 psi. 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. 4. Possible faulty Control board.
300uH FN1 L1 115V 230V L1 F1 RL2 T1 115VAC 230VAC CN1 CN1 8 7 6 5 4 3 2 1 +12VDC 115/230 OVLOAD SEC GND +28VDC SAFETY 15VAC 15VAC +15Vrms SEC GND SAFETY OVLOAD PS2 PS1 NC COM NO PRO-CUT 25 FULL SCHEMATIC: 99016 V+ NOT ALL COMPONENTS SHOWN +12VDC SPA25 +8V_SW 7 15 OVLOAD 14 SEC GND 18 4 13 4 7 11 TRANSFER 2 11 TRANSFER SW 1 1 19 24 5 EV1 DRIVER 3 14 +12VDC_SW 18 16 10 12 8 C12 13 C2b 21 23 + TRIGGER 9 12 FULL SCHEMATIC: 98044 EV2 D
● 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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