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PRO-CUT 60
IM399-D
(Single Phase)
May, 1999
PLASMA CUTTING SYSTEM
For use with all code number machines thru 10394
RETURN TO MAIN INDEX
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 thought-
ful 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.
R
OPERATOR'S MANUAL
World's Leader in Welding and Cutting Products
Premier Manufacturer of Industrial Motors
• 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.com
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Summary of Contents for Lincoln Electric PRO-CUT 60
- Page 1 PLASMA CUTTING SYSTEM For use with all code number machines thru 10394 RETURN TO MAIN INDEX 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 ...
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Page 2: Electric Shock Can Kill
WARNING 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 pur- chase a copy of “Safety in Welding &... - Page 3 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.
- Page 4 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 suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a.
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Page 5: Table Of Contents
Suggestions for Extra Utility from the PRO-CUT System...14 Maintenance Procedures ...15 Routine Maintenance...15 Troubleshooting Procedures...15-21 Troubleshooting Guide ...15-18 PRO-CUT 60 Status Lights Operating Modes...19-20 Procedure for Replacing P.C. Boards ...21 Wiring Diagram PRO-CUT 60...22 Input Supply Connection Diagrams ...23 Cutting Torch Connection Diagram...24 Parts Lists...Appendix... -
Page 6: Introductory Information
This statement appears where the information this equipment. 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! -
Page 7: Specifications
K871-1 [25Ft.(7.6m)Cable] & K871-2 [50Ft.(15.2m)Cable] Magnum PCT 60 Air Cooled Torch Input Frequency 60 Hz Output Rating 60 Amps, 115 volts, 60% Duty Cycle 60 Amps, 115 volts, Maximum Output 45 Amps, 115 volts, 100% Duty Cycle Pilot Current 22.5 amps... -
Page 8: Product Description
The PRO-CUT 60 comes standard with air regulator, coarse air filter, oil coalescing filter, and pressure gauge. The Pro-Cut 60 comes ready to use with the torch attached. Machines equipped with handheld torches are available with either 25 ft. (7.6m) or 50 ft. -
Page 9: Installation
INSTALLATION SAFETY PRECAUTIONS Read the safety precautions at the beginning of this Operator's Manual before proceeding. Only personnel that have read and under- stood this Operator’s Manual should install and operate this equipment. Machine must be connected to system ground per any national, local or other applicable electrical codes. -
Page 10: Electrical Input Connection
INPUT CONNECTIONS WARNING ELECTRIC SHOCK can kill. • Disconnect input power before proceeding. • Have a qualified electrician make the input connections. • Be sure the voltage, phase and frequency of the input power is as specified on the machine nameplate. ------------------------------------------------------------ Before starting the installation, check with the local power company if there is any question about whether... -
Page 11: Air Input Connections
CAUTION The frame of the machine must be grounded. A ground terminal marked with the symbol the left side of the input box is provided for this pur- pose. See the U.S. National Electrical Code for details on proper grounding methods. Follow other grounding instructions per the paragraph under “High Frequency Interference Protection”. -
Page 12: Pilot Arc Discussion
D. Set the Purge/Run switch to Purge. -The air should start. -The “Air Pressure” LED should be lit. -Adjust the air regulator for 60 psi (413 kPa), minimum while air is flowing. E. Set the Purge/Run switch to Run. -The air will continue to run for 20 seconds of postflow. -
Page 13: Expanded Metal
• The .035” (0.8mm) nozzle may be used for a fine cut. Larger nozzles will work and provide longer life at the expense of a larger cut. • Do not allow the torch cable or body to contact hot surface. •... -
Page 14: In All Cases
.035” (0.9mm) orifice size at outputs above the yel- low range because it will be quickly destroyed. • The PRO-CUT 60 is capable of operation with a 50 ft. (15.2m) plasma torch. Pilot arc operation may be slightly degraded with this torch installed. Sputtering... -
Page 15: Maintenance Procedures
MAINTENANCE PROCEDURE ROUTINE MAINTENANCE WARNING ELECTRIC SHOCK CAN KILL. BEFORE PERFORMING ANY MAINTE- NANCE THAT REQUIRES OPENING THE CASE OF THE POWER SOURCE: • Disconnect input power to this machine at the Disconnect switch. • Do not touch electrically live parts or internal wiring. •... - Page 16 Set the machine in purge mode. The air will turn on. Set the regulator on the back of the machine for 60 psi minimum. If the "AIR PRESSURE" LED does not light, raise the pressure slightly. If the inlet pressure is greater...
- Page 17 Check the air pressure. The pressure must be 60 psi (413 kPa) minimum while air is flowing. The "Air Pressure" LED must be lit. The machine is overheated. Allow it to cool and reset.
- Page 18 SYMPTOM The “SAFETY” LED is lit. No OCV when 2 and 4 are closed. CHECK The machine will not operate. The machine senses that the nozzle is not in place, or the operator could be exposed to dangerous volt ages if the machine were allowed to operate. Check the nozzle to be sure it is tightly in place.
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Page 19: Pro-Cut 60 Status Lights Operating Modes
FAULT, the pilot arc duty cycle is exceeded. AIR PRESSURE On whenever the air pressure is above 60 Normal conditions are purge, preflow, psi (413 kPa), there is an error condition mentioned above where air will turn on. The air will turn on for a brief time when power is first applied to machine. - Page 20 STATUS LIGHTS SAFETY It is possible that this light could turn on when power is first applied to machine. The nozzle is not in place. While cutting or gouging if the voltage between the nozzle and the work is too high, it will put the machine into SAFETY.
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Page 21: Procedure For Replacing Pc Boards
PC board. If there is damage to the PC board if replacing PC board corrects problem, return it to the local Lincoln Electric Field Service Shop. – 21 –... -
Page 22: Wiring Diagram Pro-Cut 60
July96 – 22 –... -
Page 23: Input Supply Connection Diagrams
2. CONNECT TERMINAL MARKED TO GROUND PER NATIONAL ELECTRICAL CODE. 3. REMOVE HEX NUTS AND POSITION LINKS AS SHOWN. REPLACE AND TIGHTEN ALL HEX NUTS. THE LINCOLN ELECTRIC CO., CLEVELAND, OHIO U.S.A. FIGURE 1- Triple Voltage 575 V., 60HZ. GND. USE FERRULE #10 AWG ONLY 460 V., 60HZ. -
Page 24: Cutting Torch Connection Diagram
CUTTING TORCH CONNECTION DIAGRAM FOR MAGNUM PCT 60 PLASMA TORCH A M P H E N O L C O N N E C T O R S T R A I N R E L I E F C L A M P... - Page 25 NOTES...
- Page 26 22801 St. Clair Ave. Cleveland, Ohio 44117-1199 All orders must be pre-paid (US Funds Only): Please allow up to 4 weeks for delivery. Make checks or Money Orders payable to the Lincoln Electric Company Qty. Titles Square Wave Tig 255...
- Page 27 _______________________________________________ _______________________________________________ Telephone: _______________________________________________ |_|_| |_|_| Exp Date Month Year BOOK DIVISION, The Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199 for fastest service, FAX this completed form to: 216-361-5901 Telephone: 216-383-2211 or, Price Code $5.00 $15.00 $4.50 $5.00...
- Page 28 WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO Japanese Chinese Korean Arabic READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
- Page 29 Keep your head out of fumes. Turn power off before servicing. Use ventilation or exhaust to remove fumes from breathing zone. Los humos fuera de la zona de res- Desconectar el cable de ali- piración. mentación de poder de la máquina Mantenga la cabeza fuera de los antes de iniciar cualquier servicio.
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