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IM10006
June, 2009
PLASMA 20
For use with machines having Code Number: 11578
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
THROUGHOUT. And, most
importantly, think before you act
and be careful.
OPERATOR’S MANUA
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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 purchase 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 Standar
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ii ii SAFETY 4.c. When not cutting or gouging, make certain no part of the elec- FOR ELECTRICALLY trode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard. powered equipment. 6.a. Turn off input power using the disconnect 4.d. Do not cut or gouge tanks, drums or containers until the proper switch at the fuse box before working on the steps have been taken to insure that such procedures will not equipment. cause flammable or toxic vapors from
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NOTES
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iv iv SAFETY 5. Toujours porter des lunettes de sécurité dans la zone de PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l’on pique le laitier. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce 6. Eloigner les matériaux inflammables ou les recouvrir afin de manuel aussi bien que les précautions de sûreté générales suiv- prévenir tout risque d’incendie dû aux étincelles
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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 T Th ha an nk k Y Yo ou u ••• as much pride as we have in bringing this product to you! CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip- ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchas
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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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A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - PLASMA 20 INPUT - SINGLE PHASE Standard Voltage 1Ø Input Current at Rated Output 115/1/50/60Hz (15 Amp Branch) 115 V: 20A @ 50% 115 V: 26A @ 40% 115/1/50/60Hz (20 Amp Branch with 20 Amp Plug*) RATED OUTPUT Duty Cycle AMPS 50% on 115V (15 Amp Branch) 15 A 40% on 115V (20 Amp Branch with 20 Amp Plug*) 20 A OUTPUT Open Circuit Current Pilot Current Range Voltage 310 VDC 10-20 Amps 17 Amps REQUIRED AIR FLOW RATE REQUIRED AIR INLET PRESSURE 72.5 t
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A-2 A-2 INSTALLATION Read entire Installation Section before installing the PLASMA 20. (1) Make sure the power supply chassis is connected to a good earth ground. The work terminal ground does NOT ground the machine frame. SAFETY PRECAUTIONS (2) Keep the work clamp isolated from other work clamps that have high frequency. WARNING (3) If the work clamp cannot be isolated, then keep the clamp as far as possible from other work ELECTRIC SHOCK CAN KILL. clamp connections. • Only qualified person
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A-3 A-3 INSTALLATION Use of normal 20 amp household breakers may result WARNING in over current trips. If breaker trips occur, reduce the cutting current output until nuisance trips stop. CYLINDER could explode if damaged. COMPRESSED AIR OR GAS INPUT • Keep cylinder upright and chained to a fixed support. CONNECTION • Keep cylinder away from areas A source of clean, dry air or nitrogen must be supplied where it could be damaged. to the PLASMA 20. Oil in the air is a severe problem and must be
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B-1 B-1 OPERATION DESCRIPTION SAFETY PRECAUTIONS The PLASMA 20 is a constant current, continuous WARNING control plasma cutter power source. ELECTRIC SHOCK The PLASMA 20 comes standard with an air regulator can kill. and pressure gauge. The unit is powered from a • Do not touch electrically live parts 115Vac, 20 amp input circuit with a 40% duty cycle or electrode with skin or wet rating on a 10 minute basis, with 20 amp output. The clothing. unit includes a hand-held torch with consumables an
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B-2 B-2 OPERATION USER RESPONSIBILITY CONTROLS AND SETTINGS Variation such as plate chemistry, plate surface condi- 5 4 6 tion (oil, scale), plate thickness, preheat, quench, 8 gas type, gas flow rate and equipment may produce 3 2 7 results different than those expected. Some adjust- ments to procedures may be necessary to compen- 1 sate for unique individual conditions. Test all proce- dures duplicating actual field conditions. 10 9 DESIGN FEATURES AND ADVANTAGES • Light weight • Continuous
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B-3 B-3 OPERATION CUTTING OPERATIONS CHECKING AIR QUALITY To check air quality, deactivate the torch (post-flow) BEFORE CUTTING and place a welding filter lens in front of the torch. Any WARNING oil or moisture in the air will be visible on the lens. DO NOT initiate pilot arc while checking air quality. ELECTRIC SHOCK CAN KILL. Disconnect input power by removing When preparing to cut, position the machine as close the plug from the receptacle before to the work as possible. Make sure you have a
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B-4 B-4 OPERATION • When ready to cut, place the torch near the work, NOTE: For better torch control, it is acceptable to let make certain all safety precautions have been taken the nozzle drag along the work piece surface. This and pull the trigger. will shorten nozzle life. Also, it is acceptable to place - The air will flow for a preflow time of 3 seconds a non-conductive torch guide on the work piece in and the pilot arc will start. order to achieve a cleaner cut - The pilot arc will
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B-5 B-5 OPERATION FIGURE B.2 PILOT ARC DISCUSSION SHEILD CUP The PLASMA 20 has a smooth, continuous pilot arc. The NOZZLE pilot arc is only a means of transferring the arc to the work- GAS DIFFUSER RING piece for cutting. Repeated pilot arc starts, in rapid succes- sion, is not recommended as these starts will generally ELECTRODE reduce consumable life. Occasionally, the pilot arc may TORCH HEAD sputter or start intermittently. This is aggravated when the ASSEMBLY consumables are worn or the
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D-1 D-1 MAINTENANCE PERIODIC MAINTENANCE WARNING ELECTRIC SHOCK can kill. WARNING • Have an qualified person service ELECTRIC SHOCK CAN KILL. this equipment. • Turn off machineand disconnect • Disconnect input power by removing input power by removing the plug plug from receptacle before assem- from the receptacle switch before bling or disassembling torch parts, tightening, cleaning or replacing or torch and lead assemblies. consumables. • Do not touch electrically hot parts. ---------------
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D-2 D-2 MAINTENANCE COMPRESSED AIR FILTER The unit is supplied with a filter for the compressed air and fitted with a manual drain for condensation. (Drain is located on the bottom of the filter). Purge periodical- ly to remove the water in the filter by opening the drain knob. Do not use solvents to clean the filter; use soapy water only. PLASMA 20
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E-1 E-1 TROUBLESHOOTING HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual. _______________________________________________________________
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E-2 E-2 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION GREEN LED OFF, Fan not operat- 1. Plug unit into 115V outlet. ing. No Input Power. 2. Reset Breaker. GREEN LED ON, YELLOW 1. Make sure the unit has not been Overtemperature / under pressure operated beyond duty cycle limits. LED ON. Unit is overheated. 2. Air Flow obstructed. GREEN LED ON, YELLOW Over 1. Air not connected or pressure too tempera
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F-1 F-1 DIAGRAMS PLASMA 20 5 CONTROL BOARD DISPLAY BOARD INVERTER BOARD 11/ 07 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.
