Lincoln Electric IM637-A manual

PRO-CUT TM 55 OPERA TOR’S MANUAL IM637-A March, 2005 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 MANU[...]

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[...]

FOR ELECTRICALL Y powered equipment. 6.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 6.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s rec- ommendations. 6.c. Ground the equipment in accordance with the U.S. National Electrical[...]

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iv SAFETY iv 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. Les circuits ?[...]

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! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay par[...]

vi vi T ABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1 Safety Precautions...........................................................[...]

vii vii T ABLE OF CONTENTS Page Maintenance ....................................................................................................Section D Safety Precautions ................................................................................................D-1 Input Filter Capacitor Discharge Procedure ..................................[...]

A-1 INST ALLA TION A-1 RA TED OUTPUT OUTPUT RECOMMEND INPUT WIRE AND FUSE SIZES REQUIRED GAS FLOW RA TE REQUIRED GAS INLET PRESSURE TECHNICAL SPECIFICA TIONS - PRO-CUT 55 Duty Cycle 50% Duty Cycle 100% Duty Cycle Current Range 25-60 Amps Open Circuit V oltage MAX 335 VDC For all plasma cutting applications Based on U.S. National Electrical Code Amb[...]

A-2 INST ALLA TION PRO-CUT 55 A-2 SAFETY PRECAUTIONS Read entire Installation Section before installing the PRO-CUT 55. 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 equip- ment. • Do not [...]

A-3 INST ALLA TION PRO-CUT 55 A-3 INPUT ELECTRICAL CONNECTIONS 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 should be connected only by a quali- fied electrician. Installation shoul[...]

A-4 INST ALLA TION PRO-CUT 55 A-4 2. If the ground screw assembly is loose, tighten the assembly to the base before installing the new ground lead. Install the green lead on the ground screw assembly, replace the plain washer and lock washer, then tighten nut. Install in accordance with all local and national electrical codes. 3. Connect the new co[...]

A-5 INST ALLA TION PRO-CUT 55 A-5 GAS INPUT CONNECTIONS Supply the PRO-CUT 55 with clean compressed air or nitrogen. • Supply pressure must be between 80 psi and 150 psi. • Pressure guage, located on the front of the machine, should be set to approximately 70 PSI for a 25 ft. torch and 75 PSI for a 50 ft. torch while gas is flowing (purging or [...]

B-1 OPERA TION PRO-CUT 55 B-1 SAFETY PRECAUTIONS Read and understand this entire section before oper- ating the machine. NOTE: All P.C. boards are protected by a moisture resis- tant coating. When the plasma cutter is operated, this coat- ing will "bake off" of certain power resistors that normally operate at high temperatures emitting so[...]

B-2 OPERA TION B-2 USER RESPONSIBILITY Because design, fabrication, erection and cutting vari- ables affect the results obtained in applying this type of information, the serviceability of a product or struc- ture is the responsibility of the user. Variation such as plate chemistry, plate surface condition (oil, scale), plate thickness, preheat, qu[...]

B-3 OPERA TION B-3 CUTTING CAP ABILITY The PRO-CUT 55 is rated at 55 amps, at 50% duty cycle on a 10 minute basis (runs 55 amps for 5 minutes, then idling for 5 minutes) or 40 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 t[...]

B-4 OPERA TION B-4 LIMIT A TIONS Do not exceed output current and duty cycle rating of machine. Do not use the PRO-CUT 55 for pipe thaw- ing. CONTROLS AND SETTINGS When preparing to cut or gouge, 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. [...]

B-5 OPERA TION B-5 • 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 OPERA TION B-6 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 intermi[...]

B-7 OPERA TION B-7 Suggestions for Extra Utility from the PRO-CUT System: 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. When this happens turn the power off, remove the nozzle and electrode[...]

C-1 ACCESSORIES C-1 AL W A YS 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[...]

D-1 MAINTENANCE D-1 PRO-CUT 55 INPUT FIL TER CAP ACIT OR DISCHARGE PROCEDURE 1 . Turn off input power or disconnect input power lines. 2. Remove the 5/16" hex head screws from the side and top of the machine and remove wrap-around machine cover. 3. Be careful not to make contact with the capacitor terminals that are located on the top and bott[...]

D-2 MAINTENANCE D-2 ROUTINE 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 wi[...]

E-1 TROUBLESHOOTING E-1 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION This Troubleshooting Guide is provided to help you locate and repair possible machine[...]

E-2 TROUBLESHOOTING E-2 PRO-CUT 55 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBLEMS (SY[...]

E-3 TROUBLESHOOTING E-3 PRO-CUT 55 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBLEMS (SY[...]

E-4 TROUBLESHOOTING E-4 PRO-CUT 55 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBLEMS (SY[...]

E-5 TROUBLESHOOTING E-5 PRO-CUT 55 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBLEMS (SY[...]

E-6 TROUBLESHOOTING E-6 PRO-CUT 55 Observe all Safety Guidelines detailed throughout this manual ST A TUS BOARD INDICA TORS SYMPTOM Machine is unresponsive immediately after power-up. The Air Low LED is lit The Safety LED is flashing The Safety LED is lit and steady The Thermal LED is lit The “ Ready ” , “ Air Low ” and “ Thermal ” LED [...]

E-7 TROUBLESHOOTING E-7 PRO-CUT 55 Observe all Safety Guidelines detailed throughout this manual CONSUMABLE RELA TED SAFETY LED TROUBLESHOOTING A. If the Safety LED is LIT AND STEADY , perform the following: 1. If the reset button (when pressed) does not turn the Safety LED off, the reset button or associated wiring may be faulty. See the wiring di[...]

F-1 DIAGRAMS F-1 PRO-CUT 55 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number. [...]

F-2 DIAGRAMS F-2 PRO-CUT 55 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.[...]

F-3 DIAGRAMS F-3 PRO-CUT 55 LEFT SIDE OF MAC HINE J5,J22,J36 J35 J4,J10, J1,J20, J33 ELECTRICAL SYMBOLS PER E1537 L12067 12 3 4 13 4 6 1 5 4 1 8 7 6 12 15 5 10 1 6 8 1 16 1 9 WIRING DIAGRAM (CODES 11013 & 11014) R = RED OR PINK (VIEWED FROM COMPONENT SIDE OF BOARD) W = WHITE CONNECTOR CAVITY NUM BERING SEQUENCE G = GREEN B = BLACK OR GRAY COLOR[...]

F-4 DIAGRAMS F-4 PRO-CUT 55 ELEC ELEC xxxxxxx CONTROL S4 PRIMARY LEFT SIDE OF MAC HINE 360 J33 J37 S2 RESET J5,J22,J36 15 14 217 216 J35 223 J4,J10, S3 PSI_SET J1,J20, J33 54 B U R S1 V W R POWER W 53 8 12V N 56 H1 R N 51 2 24V 203A 206 C1 1200/450 POWER 4 1 5 2 6 3 503 T3 277A 221 400- 460VAC 200- ELECTRICAL SYMBOLS PER E1537 RECONNECT L12066 12 3[...]

F-5 DIAGRAMS F-5 PRO-CUT 55 12.60 11.00 25.94 19.50 2.95 DIMENSION PRINT PR O-CUT 55 10-31-97D M18806 OFF OFF XXXX XXXX XXXX XXXX XXXX XXXX PRO-CUT 55[...]

NOTES PRO-CUT 55[...]

NOTES PRO-CUT 55[...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’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 F ABRICANTE P ARA E[...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIPAMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes f[...]

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