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SVM140-A
July, 2005
™
PRO-CUT 55
For use with machine code numbers Below 11000
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 thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before
you act and be careful.
SERVICE
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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 safe- PLASMA ARC can injure. ty 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 goug- ing out of position or in confined places. Always wear safety 7.a. Keep your body away from nozzle and glasses with side shields when in a cutting or gouging area. plasma arc. 4.h. Connect the work cable to
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iii iii NOTES PRO-CUT 55 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
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iv iv MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page Safety.................................................................................................................................................i-iii Installation.............................................................................................................................Section A Operation...............................................................................................................................Section
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Section A-1 Section A-1 TABLE OF CONTENTS - INSTALLATION SECTION - Installation Technical Specifications .............................................................................................................A-2 Safety Precautions......................................................................................................................A-4 Select Suitable Location.............................................................................................................A-4 Stack
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A-2 A-2 INSTALLATION TECHNICAL SPECIFICATIONS - PRO-CUT 55 INPUT RATINGS Single Phase Input Input Currents Rated Output Amps Voltage and Hertz 208/1/60 60 55 230/1/60 55 55 460/1/60 30 55 208/1/60 44 40 230/1/60 40 40 460/1/60 23 40 Three Phase Input Input Currents Rated Output Amps Voltage and Hertz 208/3/60 31 55 230/3/60 28 55 460/3/60 17 55 208/3/60 23 40 230/3/60 21 40 460/3/60 15 40 IDLE CURRENT AND WATTS 230/1/60 0.42 Amps 98 Watts RATED OUTPUT Duty Cycle Rated Output Amps 50% 55 100% 40
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A-3 A-3 INSTALLATION TECHNICAL SPECIFICATIONS (Cont’d) - PRO-CUT 55 GAS REQUIREMENTS Required Gas Flow Rate Required Gas Inlet Pressure 70 PSI @ 360 SCHF 80 to 150 PSI (4.8 Bar. @ 10160 LHR) (5.4 Bar. to 10.2 Bar.) (6 CFM) RECOMMENDED INPUT WIRE AND FUSE SIZES For all plasma cutting applications based on U.S. National Electrical Code Ambient Temperature 30°C or Less AC Input Voltage Fuse (Super Lag) Type 75°C at Circuit Breaker Copper Wire in Conduit AWG 60 Hertz (Delay Type) (IEC) Sizes 2 Inpu
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A-4 A-4 INSTALLATION Read this entire installation section before you LIFTING AND MOVING start installation. WARNING SAFETY PRECAUTIONS FALLING EQUIPMENT can cause injury. WARNING • Do not use the pull handle on the ELECTRIC SHOCK can kill. optional undercarriage, if installed, to lift the machine. This handle is • Turn the input power OFF at the not designed to support the full disconnect switch or fuse box weight of the machine. Using it to and discharge input capacitors lift the machine
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A-5 A-5 INSTALLATION GROUND CONNECTION INPUT CONNECTIONS The frame of the Pro-Cut 55 must be properly ground- ed. A ground terminal marked with the symbol is WARNING mounted on the case bottom directly behind the input power switch for this purpose. The ground lead of the ELECTRIC SHOCK can kill. input power cord that is attached to the machine must • Have a qualified electrician install and be connected to this ground terminal. See the service this equipment. National Electric Code for d
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A-6 A-6 INSTALLATION FIGURE A.2 – RECONNECTION DIAGRAM RECONNECT PROCEDURE When received directly from the factory, the machines are internally connected for 230 VAC. Reconnection RECONNECT PROCEDURE will be necessary if a higher input voltage is used. To WARNING reconnect the Pro-Cut to 460 VAC or to connect back to 230 VAC, follow the directions as outlined below. • Disconnect input power before inspecting or servicing machine. Follow this procedure ONLY while the Pro-Cut is dis- • Do
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A-7 A-7 INSTALLATION FIGURE A.3 - COMPRESSED GAS CONNECTION GAS INPUT CONNECTIONS Supply the Pro-Cut 55 with clean compressed air or nitrogen. • Supply pressure must be between 80 psi and 150 1 psi. • Flow rate should be approximately 6.0 cfm (170 I/min.). NOTE: Oil in the air supply to the Pro-Cut 55 can cause severe problems. Use only a clean air 2 supply. • Connect the gas supply to the Pro-Cut 55’s 3 pneumatic nipple at the air filter. See Figure A.3. • Compressed gas should be supp
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A-8 A-8 INSTALLATION FIGURE A.4 - TORCH CONNECTION OUTPUT CONNECTIONS AT CASE FRONT TORCH CONNECTION The Pro-Cut 55 is supplied from the factory with a PCT 80 cutting torch. Additional cutting torches can be XXXX XXXX XXXX XXXX ordered from the K1571 series. Hand-held and mech- anized torches come with 25 or 50 foot cables. All torches are connected to the Pro-Cut with a quick PRO-CUT 55 connect at the case front for easy change over. See Figure A-4. OFF For more information on the torch and
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Section B-1 Section B-1 TABLE OF CONTENTS - OPERATION SECTION - Operation...............................................................................................................................Section B Safety Instructions......................................................................................................................B-2 General Description ....................................................................................................................B-3 Recommend
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B-2 B-2 OPERATION OPERATING INSTRUCTIONS Read and understand this entire section of operating instructions before operating the machine. SAFETY INSTRUCTIONS WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrodes with your skin or wet cloth- ing. • Insulate yourself from the work and ground. • Always wear dry, insulating gloves. FUMES AND GASES can be dangerous. • Keep your head out of fumes. • Use ventilation or exhaust to remove fumes from breathing zone. CUTTIN
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B-3 B-3 OPERATION GENERAL DESCRIPTION DESIGN FEATURES AND ADVANTAGES The Pro-Cut 55 is an inverter based constant current, continuous control plasma cutting power source. It The microprocessor controlled Pro-Cut 55 design provides superior and reliable starting characteristics, makes plasma cutting and gouging tasks uncompli- cutting visibility and arc stability. When cutting cated. This list of design features and advantages will expanded metal, the Pro-Cut 55 out-performs the help you underst
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B-4 B-4 OPERATION CUTTING CAPABILITY The Pro-Cut 55 is rated at 55 amps, at 50% duty cycle on a 10 minute basis or 40 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 operating temperature. Figure B.1 shows the cut capacity of the Pro-Cut 55 when cutting mild steel. The graph plots cut thickness vs. torch travel speed with a torch standoff of 0.15 in. (3.8mm). Example: 0.25 material Amps Speed (IPM
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B-5 B-5 OPERATION CONTROLS AND SETTINGS PILOT ARC CONSIDERATIONS FIGURE B.2 - CASE FRONT CONTROLS 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 9 8 7 rapid succession, is not recommended as these starts 6 will generally reduce consumable life. Occasionally, the pilot arc may sputter or start intermittently. This is XXXX XXXX XXXX XXXX 5 aggravated when the consumables are worn or
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B-6 B-6 OPERATION - The gas will immediately turn off. The pressure 5° - 15° Leading Angle gauge may show an increase in pressure after the air turns off, but this is normal. Do NOT reset the pressure while the air is NOT flowing. • When ready to cut, place the torch near the work, make certain all safety precautions have been taken and pull the trigger. Direction of Travel - The air will flow for a preflow time of 2 seconds and the pilot arc will start. (This is true unless the machine i
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B-7 B-7 OPERATION PREHEAT TEMPERATURE FOR WARNING PLASMA CUTTING ELECTRIC SHOCK can kill. Preheat temperature control is not necessary in most applications when plasma arc cutting or gouging. • Turn off machine at the disconnect Preheat temperature control may be necessary on switch on the front of the machine high carbon alloy steels and heat treated aluminum for before tightening, cleaning or replac- crack resistance and hardness control. Job condi- ing consumables. tions, prevailing codes,
