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IM595-A
TM May, 2004
PRO-CUT 80
For use with machines having Code Numbers: 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 thought-
ful operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHO
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i i SAFETY PLASMA CUTTING or GOUGING can be hazardous. 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 & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Stand
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ii ii SAFETY 4.g. Sparks and spatter are thrown from the plasma arc. Wear PLASMA ARC can injure. 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 7.a. Keep your body away from nozzle and plasma arc. safety glasses with side shields when in a cutting or gouging area. 4.h. Connect the work cable to the
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NOTES
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iv iv SAFETY zones où l’on pique le laitier. PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de Pour votre propre protection lire et observer toutes les instructions prévenir tout risque d’incendie dû aux étincelles. et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- 7. Quand on ne soude pas, poser la pince à une endroit isolé de antes: la masse. Un court-circuit accidental peut provo
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v v for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product Thank You ��� 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
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vi vi TABLE OF CONTENTS Page Installation.......................................................................................................................Section A Technical Specifications.......................................................................................................A-1 Safety Precautions ...............................................................................................................A-2 Select Proper Location ..........................................
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vii vii TABLE OF CONTENTS Page Maintenance ....................................................................................................Section D Safety Precautions ................................................................................................D-1 Input Filter Capacitor Discharge Procedure ..........................................................D-1 Routine Maintenance.............................................................................................D-2 Periodi
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A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - PRO-CUT 80 INPUT THREE PHASE SINGLE PHASE Standard Input Current Standard Input Current Voltage at Rated Output Model Voltage at Rated Output Model 208/230/460 48/44/25 50/60 Hz 208/230/460 87/81/48 50/60Hz 200/380-415 46/27/24 50/60 Hz 460/575 25/20 50/60 Hz RATED OUTPUT Duty Cycle AMPS VOLTS 60% Duty Cycle 80 140 100% Duty Cycle 60 130 OUTPUT Current Open Circuit Pilot Current Range Voltage MAX 20 Amps @ 100% Duty Cycle 335 VDC 35-85 Amps REQU
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A-2 A-2 INSTALLATION Read entire Installation Section before installing the LIFTING AND MOVING PRO-CUT 80. Either the front or rear handles or both may be used to lift or move the machine. SAFETY PRECAUTIONS DO NOT use the pull handle on the optional undercar- riage, if installed, to lift the machine. This handle is not WARNING designed to support the full weight of the machine and using it to lift the machine could cause personal injury ELECTRIC SHOCK CAN KILL. or damage to the machine. � On
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A-3 A-3 INSTALLATION CORD REMOVAL: INPUT ELECTRICAL CONNECTIONS 1. Unplug line cord from the receptacle. WARNING Before installing the machine, check that input supply voltage, phase, and frequency are the same as the NOTE: DO NOT PERFORM THE NEXT STEP machine's voltage, phase, and frequency as specified UNTIL THE HIGH VOLTAGES INSIDE THE on the machine's rating plate. MACHINE HAVE BEEN ALLOWED TO DISSIPATE, APPROXIMATELY TWO MINUTES. The Pro-Cut 80 should be connected only by a quali- ----
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A-4 A-4 INSTALLATION For 380 - 415 VAC Supplies: FRAME GROUNDING The AC wave form peak voltage must be below 840 The frame of the Pro-Cut 80 must be properly ground- volts. ed. A ground terminal marked is mounted on the The RMS voltage must be 400 VAC +/- 10%. case bottom directly behind the input power switch for this purpose. The cable that is sent attached to the For 460 VAC Supplies: machine is connected to this ground terminal. See the National Electric Code for details on prope
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A-5 A-5 INSTALLATION GAS INPUT CONNECTIONS � While it is recommended that an in line prefilter be placed ahead of each PRO-CUT that may be Supply the PRO-CUT 80 with clean compressed air or installed in a shared air supply line, one large inline nitrogen. prefilter may instead be used to accommodate sev- 2 eral PRO-CUTs simultaneously. If a shared prefilter � Supply pressure must be between 80 psi(5.6kg/cm ) 2 is desired, it must be rated to provide the necessary and 120 psi(8.4kg/cm ). flow
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B-1 B-1 OPERATION Read and understand this entire section before oper- DESCRIPTION ating the machine. The PRO-CUT 80 is a constant current, continuous con- trol plasma cutting power source. It provides superior and reliable starting characteristics, cutting visibility and SAFETY PRECAUTIONS arc stability. When cutting expanded metal, the PRO- CUT 80 out performs the competition due to its quick, WARNING clean response to arc transfers. The power supply design provides high transfer-to-cut distan
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B-2 B-2 OPERATION - Input over voltage protection. USER RESPONSIBILITY - Bright 3.0 second timed pilot arc. Because design, fabrication, erection and cutting vari- ables affect the results obtained in applying this type - Purge momentary push button. of information, the serviceability of a product or struc- ture is the responsibility of the user. Variation such as - Air regulator and pressure gage located on the front plate chemistry, plate surface condition (oil, scale), of machine for con
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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. Figure B.1 shows the cut capacity of the PRO-CUT 80 when cutting mild steel. The graph plots cut thickness vs. torch travel speed with a to
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B-4 B-4 OPERATION � Set the output current control knob at maximum LIMITATIONS position for high cutting speed and less dross forma- tion. Reduce the current, if desired to reduce the Do not exceed the output current and duty cycle rating kerf (cut) width, heat affected zone or travel speed of machine. Do not use the PRO-CUT 80 for pipe as required. thawing. GAS PRESSURE SETTINGS CONTROLS AND SETTINGS � Push-in and hold the Purge button to check or set the gas pressure. Pull the pressure regul
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B-5 B-5 OPERATION ANGLE OF APPROACH � Hold the nozzle standoff 1/8” (3.2mm) to 3/16” Gloves Required (4.8mm) above the workpiece during cutting. Do not let the nozzle touch the work or carry a long arc. 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. ANGLE MAINTAINED THROUGHOUT GOUGE 5° - 15° Leading Angle SAFETY LED � If the "SAFETY" LED light
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B-6 B-6 OPERATION Thick Sections of Metal PILOT ARC DISCUSSION The PRO-CUT has a smooth, continuous pilot arc. Torch Standoff Machine Output Setting 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 45 aggravated when the consumables are worn or the air pressure is too
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B-7 B-7 OPERATION h. Set air pressure to recommended setting. A higher Suggestions for Extra Utility from the or lower pressure will cause turbulence in the PRO-CUT System: plasma arc, eroding the orifice of the nozzle tip. WARNING i. Use only Lincoln consumable parts. These ELECTRIC SHOCK CAN KILL. parts are patented and using any other � Turn off machine at the disconnect replacement consumables may cause damage switch on the front of the machine to the torch or reduce cut quality. befor
