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IM648-B
June, 2003
RED-D-ARC
PYTHON
For use with machines having Code Numbers:
10627, 10656
11025, 11026
OPERATOR’S MANUAL
Red-D-Arc Spec-Built Welding Equipment
This RED-D-ARC cutter is built to RED-D-ARC Extreme Duty
design specifications by Lincoln Electric.
Safety Depends on You
This cutter 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
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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 PLASMA ARC can injure. safety 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 gouging out of position or in confined places. Always wear 7.a. Keep your body away from nozzle and safety glasses with side shields when in a cutting or gouging plasma arc. area. 4.h. Connect the work cable to the
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iii iii NOTES PYTHON
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iv iv SAFETY zones où l’on pique le laitier. PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de Pour votre propre protection lire et observer toutes les instructions prévenir tout risque d’incendie dû aux étincelles. et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- 7. Quand on ne soude pas, poser la pince à une endroit isolé de antes: la masse. Un court-circuit accidental peut provo
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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 Thank You ��� as much pride as we have in bringing this product to you! Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment
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vi TABLE OF CONTENTS Page Installation.......................................................................................................................Section A Technical Specifications.......................................................................................................A-1 Safety Precautions ...............................................................................................................A-2 Select Proper Location .............................................
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vii TABLE OF CONTENTS Page Maintenance ....................................................................................................Section D Safety Precautions ................................................................................................D-1 Input Filter Capacitor Discharge Procedure ..........................................................D-1 Routine Maintenance.............................................................................................D-2 Periodic Ma
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A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - PYTHON INPUT THREE PHASE SINGLE PHASE Standard Input Current Standard Input Current Voltage at Rated Output Model Voltage at Rated Output Model 208/230/460 48/44/25 50/60 Hz 208/230/460 87/81/48 50/60Hz 460/575 28/20 50/60 Hz RATED OUTPUT Duty Cycle AMPS VOLTS 60% Duty Cycle 80 140 100% Duty Cycle 60 130 OUTPUT Current Open Circuit Pilot Current Range Voltage MAX 20 Amps @ 100% Duty Cycle 335 VDC 35-85 Amps REQUIRED GAS FLOW RATE REQUIRED GAS IN
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A-2 A-2 INSTALLATION Read entire Installation Section before installing the LIFTING AND MOVING PYTHON. Either the front or rear handles or both may be used to lift or move the machine. SAFETY PRECAUTIONS DO NOT use the pull handle on the optional undercar- riage, if installed, to lift the machine. This handle is not WARNING designed to support the full weight of the machine and using it to lift the machine could cause personal injury ELECTRIC SHOCK CAN KILL. or damage to the machine. � Only q
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A-3 A-3 INSTALLATION INPUT ELECTRICAL CORD INSTALLATION: CONNECTIONS 1. Feed the new cord through the cable connector Before installing the machine, check that input supply and into the machine. voltage, phase, and frequency are the same as the 2. If the ground screw assembly is loose, tighten the machine's voltage, phase, and frequency as specified assembly to the base before installing the new on the machine's rating plate. ground lead. Install the green lead on the ground screw assembly,
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A-4 A-4 INSTALLATION FRAME GROUNDING USE ON ENGINE DRIVEN POWER SUPPLIES The frame of the PYTHON must be properly ground- The PYTHON can be used on engine driven power ed. A ground terminal marked is mounted on the supplies. However, the following AC Wave Form case bottom directly behind the input power switch for Voltage and Input Power Restrictions do apply. this purpose. The cable that is sent attached to the machine is connected to this ground terminal. See the AC Wave Form Restr
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A-5 A-5 INSTALLATION � While it is recommended that an inline prefilter be GAS INPUT CONNECTIONS placed ahead of each PRO-CUT, that may be in stalled in a shared air supply line, one large in line Supply the PYTHON with clean compressed air or prefilter may instead be used to accommodate sev- nitrogen. eral PRO-CUT’s simultaneously. If a shared pre is desired, it must be rated to provide the necessary � Supply pressure must be between 80 psi flow rate, as specified, to ensure proper operatio
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B-1 B-1 OPERATION NOTE: All P.C. boards are protected by a moisture resistant Read and understand this entire section before oper- coating. When the plasma cutter is operated, this coating ating the machine. will "bake off" of certain power resistors that normally oper- ate at high temperatures emitting some smoke and odor for SAFETY PRECAUTIONS a short time. These resistors and the P.C. board beneath them may become darkened. This is a normal occurrence WARNING and does not damage the component
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B-2 B-2 OPERATION - Input over voltage protection. USER RESPONSIBILITY - Bright 3.0 second timed pilot arc. Because design, fabrication, erection and cutting vari- ables affect the results obtained in applying this type - Purge momentary push button. of information, the serviceability of a product or struc- ture is the responsibility of the user. Variation such as - Air regulator and pressure gage located on the front plate chemistry, plate surface condition (oil, scale), of machine for con
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B-3 B-3 OPERATION CUTTING CAPABILITY 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 cutting mild steel. The graph plots cut thickness vs. torch travel speed with a torch standoff of 0.15". Example: 0.5” material may be cut at a setting of 55 am
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B-4 B-4 OPERATION 2. GAS PRESSURE SETTINGS. LIMITATIONS � Push-in and hold the Purge button to check or set the gas pressure. Pull the pressure regulator cap out and turn it to set the pressure. Do not exceed the output current and duty cycle rating - Adjust the gas regulator for 70 PSI for 25’ torch- of machine. Do not use the PYTHON for pipe thawing. es or 75 PSI for 50’ torches. - Release the Purge button. CONTROLS AND SETTINGS - The gas will immediately turn off. The pressure gage may s
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B-5 B-5 OPERATION ANGLE OF APPROACH � 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. TORCH HELD AT 0 45 ANGLE � Keep moving while cutting. Cut at a steady speed THROUGHOUT GOUGE without pausing. Maintain the cutting speed so that the arc leg is 10° to 20° behind the travel direction. ANGLE MAINTAINED THROUGHOUT GOUGE 5° - 15° Leading Angle 1. SAFETY LED � If the "SAFETY" LED lights at any time,
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B-6 B-6 OPERATION THICK SECTIONS OF METAL: PILOT ARC DISCUSSION The PYTHON has a smooth, continuous pilot arc. Torch Standoff Machine Output Setting 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 intermittently. This is 3 aggravated when the consumables are worn or the air pressure is too h
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B-7 B-7 OPERATION Suggestions for Extra Utility from the h. Set air pressure to recommended setting. A PYTHON System: higher or lower pressure will cause turbulence in the plasma arc, eroding the orifice of the WARNING nozzle tip. ELECTRIC SHOCK CAN KILL. � Turn off machine at the disconnect i. Use only Lincoln consumable parts. These switch on the front of the machine parts are patented and using any other before tightening, cleaning or replacing replacement consumables may cause damage co
