Lincoln Electric IM648-B manual

RED-D-ARC PYTHON IM648-B June, 2003 Red-D-Ar c Spec-Built W elding Equipment This RED-D-ARC cutter is built to RED-D-ARC Extreme Duty design specifications by Lincoln Electric. Safety Depends on Y ou This cutter is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thoughtful operati[...]

PYTHON 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 S[...]

PYTHON 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 Ele[...]

PYTHON iii NOTES iii[...]

PYTHON iv SAFETY iv Mar. ‘93 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:[...]

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

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

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 TECHNICAL SPECIFICA TIONS - PYTHON RA TED OUTPUT OUTPUT RECOMMEND INPUT WIRE AND FUSE SIZES REQUIRED GAS FLOW RA TE REQUIRED GAS INLET PRESSURE Duty Cycle 60% Duty Cycle 100% Duty Cycle Current Range 35-85 Amps Open Circuit V oltage MAX 335 VDC For all plasma cutting applications Based on U.S. National Electrical Code Ambient[...]

A-2 INST ALLA TION A-2 Read entire Installation Section before installing the PYTHON. SAFETY PRECAUTIONS 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 electricall[...]

PYTHON A-3 INST ALLA TION 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 PYTHON should be connected only by a qualified electrician. Installation should be made [...]

PYTHON A-4 INST ALLA TION A-4 FRAME GROUNDING The frame of the PYTHON must be properly ground- ed. 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 g[...]

PYTHON A-5 INST ALLA TION A-5 GAS INPUT CONNECTIONS Supply the PYTHON with clean compressed air or nitrogen. • Supply pressure must be between 80 psi and 120 psi. • Pressure gage, 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 cutting).[...]

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

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[...]

PYTHON B-3 OPERA TION B-3 CUTTING CAP ABILITY The PYTHON is rated at 80 amps, at 60% duty cycle on a 10 minute basis or 60 amps, at 100% duty cycle. If the duty cycle is exceeded, a thermal protector will shut off the output of the machine until it cools to the normal oper- ating temperature. Figure B.1 shows the cut capacity of the PYTHON when cut[...]

B-4 OPERA TION B-4 LIMIT A TIONS Do not exceed the output current and duty cycle rating of machine. Do not use the PYTHON for pipe thawing. 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. It[...]

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 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. • Use [...]

B-6 OPERA TION B-6 PILOT ARC DISCUSSION The PYTHON 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 intermit[...]

B-7 OPERA TION B-7 Suggestions for Extra Utility from the PYTHON 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 PYTHON's safety circuit. When this happens turn the power off, remove the nozzle and electrode a[...]

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 PYTHON. • The patented VORTECH ™ nozzle provides an extra “ kick ” of swirl as the arc exits the nozzle which improves cutting performance. No other nozzle has[...]

PYTHON D-1 MAINTENANCE D-1 INPUT FIL TER CAP ACITOR 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 bottom of[...]

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[...]

PYTHON 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 [...]

E-2 TROUBLESHOOTING E-2 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 (SYMPTOMS) POS[...]

E-3 TROUBLESHOOTING E-3 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 (SYMPTOMS) POS[...]

E-4 TROUBLESHOOTING E-4 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 (SYMPTOMS) POS[...]

E-5 TROUBLESHOOTING E-5 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 (SYMPTOMS) POS[...]

PYTHON E-6 TROUBLESHOOTING E-6 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 ’ [...]

F-1 DIAGRAMS F-1 PYTHON 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.. N.C[...]

F-2 DIAGRAMS F-2 PYTHON L10936 10K 5 5 212 10 219 13 14 212 1 POWER U - ELEC XFER X40 X4 5,6 AIR SOL 7,8 ELEC SOL J34 J32 3 TRIGGER 11 12 CHOKE 0.6A 5 TP3 B N CASE FRONT BASE PROTECTIVE BONDING CIRCUIT A A 4 S LEFT SIDE OF MACHINE S BK-IN 2 R 218 3 S BK-OUT 217 S3 PSI_SET 302 E C 51 404 R N CONTROL 8 D R 214 10 B A X1 S2 RESET 347 7 1 J4,J10, J30 4[...]

F-3 DIAGRAMS F-3 PYTHON L12068 WI R ING D IAGRAM (FOR CODE 11025) 14 13 212 10 219 POWER 5 64 H5 U 10K 212 56 TP1 5 C C 207A 1 9 - ELEC XFER X40 X4 J36 J38 1,7 TRI GGER CHOKE 0.6A 5 TP3 B N CASE FRONT BASE PROTECTIVE BONDING CIRCUIT A A 4 S LEFT SIDE OF MACHINE S BK-IN 2 R 218 3 S BK-OUT 217 S3 PSI_SET 302 E C 51 404 R N CONTROL D R 214 10 B A X1 S[...]

F-4 DIAGRAMS F-4 PYTHON L12069 WI RIN G DIAGRAM (FOR CODE 11026) A ELECTRICAL SYMBOLS PE R E1537 N.C. J3 2 CONTROL 10K 343 K J PRESSURE I 7 W G F D 369 4 218 212 J5 J4 209 501 205 209 - B O T - O U T 231A I X1 S TO P-OUT TRANSFORMER CURRENT T3 A 4 9 1 1 (VIEWED FROM COMPONENT SIDE OF BOARD) N.D. C1 & C2 CAPACITORS A RE A MATCHED SET. J3 1 Y = Y[...]

F-5 DIAGRAMS F-5 PYTHON 16.41 22.50 3.50 13.71 29.50 CC-UF M19195 DIMENSION PRINT - PYTHON P YTHON[...]

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 EQUIP AMENTO 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 [...]

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