Lincoln Electric IM491-B manual

PRO-CUT 1 25 PLASMA CUTTING PO WER SOURCE OPERA TOR’S MANUAL For use with machines having Code Numbers 10384 thru 10388 IM491-B October,1999 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 [...]

– 2 – 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 - ANS[...]

– 3 – 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 [...]

– 4 – PRÉCA UTIONS 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 à [...]

– 5 – TABLE OF CONTENTS Page Safety Precautions ............................................................................................................. 2-4 Introductory Information .......................................................................................................6 Specifications .......................................[...]

– 6 – 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 referenc[...]

– 7 – SPECIFICA TIONS Type K1394-* and K1395-* K880-1[25Ft.(7.6m)Cable] & K880-2 [50Ft.(15.2m)Cable] Magnum PCT125 Air Cooled Torch Input Frequency 50 or 60 Hz, 3ø Output Rating 125 Amps, 148 volts, 60% Duty Cycle 110 Amps, 140 volts, 80% Duty Cycle 100 Amps, 135 volts, 100% Duty Cycle Pilot Current 26 amps Pilot Duty Cycle 25% (20 seconds[...]

PR ODUCT DESCRIPTION The PRO-CUT™ 125 is a constant current, single range, continuous control plasma cutting system. The system is one of the most sophisticated on the market. It provides excellent starting characteristics, cutting visibility and arc stability. The torch has a patented safety mechanism which insures that the consumables are in pl[...]

INST ALLA TION SAFETY PRECA UTIONS ● Read the safety precautions at the beginning of this Operator's Manual before proceeding. ● Only personnel that have read and under- stood this Operating Manual should install and operate this equipment. ● Machine must be connected to system ground per any national, local or other applicable electrica[...]

Input Voltage / Hz. 230/60 460/60 220/50/60 380/50/60 440/50/60 3 Input Wires #3 (25mm 2 ) #8 (10mm 2 ) #3 (25mm 2 ) #6 (16mm 2 ) #8 (10mm 2 ) 1 Grounding Wire #8 (10mm 2 ) #8 (10mm 2 ) #8 (10mm 2 ) #8 (10mm 2 ) #8 (10mm 2 ) ELECTRICAL INPUT CONNECTION Before starting the installation, check with the local power company if there is any question abo[...]

AIR INPUT CONNECTIONS A source of clean compressed air or nitrogen must be supplied to the PRO-CUT. The supply pressure must be between 80 and 150 psi (551 and 1034 kPa). The flow rate is approximately 8.0 cfm. Oil in the air is a very severe problem and must be avoided. Remove the plastic thread protector from the regulator input port (located on [...]

F. When ready to cut, place the work lead on the piece to be cut, place the torch near the work, make certain all safety precautions have been taken and pull the trigger. -The air will flow for a preflow time of 2 seconds and the pilot arc will start. (This is true unless the machine is in postflow, then the preflow time is skipped.) -The “Output[...]

Expanded Metal: Output set near mid-range. • Cut it as you would light gauge sheet metal. • Expanded metal is pilot arc intensive. After about 30 seconds of cutting, the pilot arc will change from a bright continuous arc to a discon- tinuous one which will sputter slightly. It will stay in this mode as long as metal has been cut in the previous[...]

In All Cases: • Do not pause when cutting or gouging the metal. This is not necessary and causes opera- tional difficulty. Pausing at the edge of the work- piece causes poor consumable life and erratic operation. • Always position the torch in the best way to keep dross and hot air from burning back into it. • Do not carry a long arc. This ma[...]

MAINTENANCE PR OCEDURES R OUTINE MAINTENANCE 1. Keep the cutting or gouging area and the area around the machine clean and free of com- bustible materials. No debris should be allowed to collect which could obstruct air flow to the machine. 2 . Every few months, blow the dust off the air intakes and louvers with compressed air. 3. Check the air reg[...]

– 16 – SYMPTOM CHECK No LED’s light when the power switch is turned on. 1. Check the input power to be sure it is on. 2. Check the power line fuses and machine connection. 3. Replace line switch. The “MACHINE ON” LED is lit, but there is no 1. Check the “SAFETY” LED. If it is lit, check the response when the trigger is pulled. torch c[...]

– 17 – SYMPTOM CHECK The air begins to flow, the “OUTPUT ON” LED lights 1. Check the torch consumables to be sure they for a brief period, but no arc is established. are in tight, not dirty or greasy, and in good shape. Replace the consumables if necessary. 2. Check that CR2 engages. 3. Blow off the components in the upper compart- ment wit[...]

– 18 – SYMPTOM CHECK The “MALFUNCTION” LED is lit. 1. The FAULT circuit monitors the torch to see if it is shorted as well as internal machine failures. 2. Check the torch consumables to see if they are melted together or are simply touching each other. Tighten, clean or replace. See “Suggestions for Extra Utility from the PRO-CUT System?[...]

– 19 – SYMPTOM CHECK The “SAFETY” LED is lit. 1. The machine will not operate. The machine senses that the shield cup is not in place, or the operators could be exposed to dangerous voltages if the machine were allowed to operate. 2. Check the shield cup to be sure it is tightly in place. 3. Check the torch consumables to see if they are me[...]

– 20 – STATUS LIGHTS CONDITION SUGGESTIONS MACHINE ON Should always be on when machine is on. Normal OUTPUT ON On when there is voltage potential at the Normal torch (cutting or pilot). OUTPUT ON is blinking alternately with AIR PRESSURE when power is first There is a problem with the microprocessor, applied to machine. replace the Control PC b[...]

– 21 – STATUS LIGHTS CONDITION SUGGESTIONS SAFETY It is possible that this light could turn on If machine can be reset, it is OK to continue when power is first applied to machine. operation. The torch assembly is misconnected or Check torch connection to machine. damaged. The shield cup assembly is not in place. Securely fasten shield cup asse[...]

– 22 – PROCEDURE FOR REPLA CING PC BO ARDS Before replacing a PC board which is suspected of being defective, visually inspect the PC board in ques- tion for any damage to any of its components and conductors on the back of the board. If there is no visible damage to the PC board, install a new one and see if this remedies the problem. If the p[...]

– 23 – NO TES[...]

– 24 – PCT 125 AMP PLASMA TORCH 2-10-92 Parts List P-210-C 1 7 6 12 5 9 4 11 13 10 2 2 3[...]

– 25 – PCT 125 AMP PLASMA TORCH Parts List P-210-C.1 Mag PCT-125 Torch & Cable (25’) K880-1 1 Mag PCT-125 Torch & Cable (50’) K880-2 1 1 Cable Asbly (25’) L9371-1 1 1 Cable Asbly (50’) L9371-2 1 2 Handle Repair Kit S21087 1 * Handle (LH), Includes: Handle Nut S18773 4 * Handle (RH), Includes: Pan Handle Screw (#6-32 x .75) S1882[...]

– 26 – GENERAL ASSEMBL Y PRO-CUT 125 THREE PHASE Parts List P-207-C Drop in photos from P-207-C parts page.[...]

– 27 – GENERAL ASSEMBL Y PRO-CUT 125 THREE PHASE Parts List P-207-C.1 1 Base L8473 1 2 Base Support L8472 1 3 Foot L8284 1 * Thread Forming Screw S9225-26 8 * Caster S11124-8 2 * Thread Forming Screw S9225-28 8 4 Axle T6988-22 1 5 Wheel S17073-4 2 * Plain Washer S9262-142 2 * Cotter Pin S10750-1 2 6 Case Front Asbly See P-184-D 1 * Self Tapping[...]

– 28 – CASE BACK ASSEMBL Y Parts List P-207-D 1-7-92 L8348 5-28-93 1 2 3 4 6 5 1 Case Back L7753-1 1 2 Fan & Baffle Asbly, Includes: M15585 1 * Fan Baffle L7666 1 * Fan Blade M8678-2 1 * Fan Motor M8895-5 1 * Fan Mounting M14064 1 * Self Tapping Screw S8025-70 4 * Self Tapping Screw S8025-65 4 3 Grommet S10255-12 1 4 Rear Nameplate S19840 1[...]

– 29 – SOLENOID ASSEMBL Y Parts List P-207-E S18667-5 1 2 3 4 5 10 7 8 9 1 Hose Nipple (Male) T14557-11 1 2 Solenoid S18127-4 1 3 Pipe Tee T10366 1 4 Pressure Switch S18638-1 1 5 PC Board Plug S14156-1 1 8 Hex Nipple T11289-3 1 9 Male Run Tee S19932-1 1 10 Solenoid S18127-5 1 Part No. Item Description No. Req’d. 10-27-93[...]

– 30 – REGULA TOR AND FIL TER ASSEMBL Y 1 2 3 4 IN 6 8 9 10 Parts List P-184-E 1 Filter/Regulator Asbly M16480 1 * Filter Element (.50 ID x 1.14” Long) M16480-B 1 * Panel Mounting Nut M16480-C 1 2 Oil/Coalescing Filter S19865 1 * Filter Element (.45 ID x 1.16” Long) S18637-2 1 * Filter Element (.56 ID x 1.42” Long) S19865-A 1 3 Hex Nipple[...]

– 31 – INPUT BOX ASSEMBL Y Parts List P-207-F L8322-1 6-12-96 AC2 AC1 L1 L2 L3 L1 L2 L3 5 14 7 1 2 4 CR2 19 CR1 18 6 W V U REAR VIEW FRONT VIEW AC3 20 T2 T1 T3 17 21 1 Input Box L8285 1 2 Heat Sink L8323 1 * Thread Forming Screw S9225-8 4 4 Reconnect Panel Asbly M16365-1 1 * Insulation S18764-1 1 * Plastic Expansion Nut S14020-7 4 * Self Tappin[...]

– 32 – HI FREQ BOARD ASSEMBL Y Parts List P-207-G 6-12-96 L9320 6-12-96 1 3 2 10 12 6 PILOT WORK 14 18 17 20 1 Mounting Board Asbly S19700 1 2 Carriage Bolt T11827-23 1 * Hex Nut 1/4-20 2 * Brass Hex Nut 1/4-20 1 3 Sems Screw T10082-8 1 * Hex Nut (Brass) #10-24 1 * Wing Nut T9968-4 1 6 Carriage Bolt T11827-23 2 * Hex Nut 1/4-20 4 10 Coiler Asbl[...]

– 33 – CASE FRONT ASSEMBL Y Parts List P-184-D 2-5-93 L7713 5-28-93C 1 2 3 4 5 6 9 7 8 12 13 1 Case Front G1873-1 1 2 Nameplate (Domestic) L8315 1 2 Nameplate (Export) L8354 1 3 PC Board Asbly M16301-1 1 * Self Tapping Screw S8025-71 4 4 Reset Button (S2) T15089 1 5 Run/Purge Switch (S2) T10800-13 1 6 Potentiometer (R1) T10812-40 1 7 Spacer S18[...]

– 34 – FIGURE 1- SINGLE VOL T AGE FIGURE 1- DUAL & TRIPLE VOL T AGE 3. REMOVE HEX NUTS AND POSITION LINKS AS SHOWN. REPLACE AND TIGHTEN ALL HEX NUTS. NOTE: MACHINES ARE SHIPPED FROM FACTORY CONNECTED THE LINCOLN ELECTRIC CO., CLEVELAND, OHIO U.S.A. 2. CONNECT TERMINAL MARKED TO GROUND PER NATIONAL ELECTRICAL CODE. LINK LINK POSITIONS 575 V.[...]

– 35 – FIGURE 2 ELECTRIC TORCHES Do not operate with covers removed Disconnect input power before servicing Do not touch electrically live parts Only qualified persons should install, use or service this equipment THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A. PILOT WORK ADAPTER GAS LINE WORK LEAD PILOT LEAD MOLEX CONNECTORS CORD GRIP CONNECTO[...]

– 36 – STATUS BOARD 1 2 3 4 5 6 8 7 211 212 213 214 215 216 218 325 326 1 3 2 R1 10K 5 4 1 2 6 3 5 6 3 7 84 9 2 J2 J8 1 CONTROL BOARD 12 14 10 11 15 16 13 10 1 2 3 4 5 6 7 8 9 319 324 323 322 321 J3 J7 J6 319 PURGE/RUN SWITCH (PURGE IS OPEN) 2 3 4 1 5 6 43 9 1 27 81 2 10 11 12 31 32 G1 381 G2 382 G3 383 G4 384 G5 385 G6 386 J4 2 4 5 3 6 7 8 1 J[...]

– 37 – Now A v ailable...12th Edition The Procedure Handbook of Ar c W elding With over 500,000 copies of previous editions published since 1933, the Procedure Handbook is considered by many to be the “Bible” of the arc welding industry. This printing will go fast so don’t delay. Place your order now using the coupon below. The hardbound [...]

– 38 – W ARNING A VISO DE PRECA UCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND 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 F ABRICANT[...]

– 39 – W ARNING A VISO DE PRECA UCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIP AMENTO E AS PAR TES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to rem[...]

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