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IM590
TM
December, 2002
PRO-CUT 55
For use with machines having Code Numbers:
10473, 10474, 10475 and 10476
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.
Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:
OPERATOR’S MANUAL
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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SAFETY
4.g. Sparks and spatter are thrown from the plasma arc. Wear
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
safety glasses with side shields when in a cutting or gouging
area.
PLASMA ARC can injure.
7.a. Keep your body away from nozzle and
plasma arc.
4.h. Connect the work cable to the work as close to the cutting or
gouging area as practical. Work cables connected to the build-
ing framework or other locations away from the cutting or
gouging area increase the possibility of the current passing
through lifting chains, crane cables or other alternate circuits.
This can create fire hazards or overheat lifting chains or
cables until they fail.
7.b. Operate the pilot arc with caution. The pilot arc is capable of
burning the operator, others or even piercing safety clothing.
CYLINDER may explode
if damaged.
5.a. Use only compressed gas cylinders contain-
ing the correct gas for the process used and
properly operating regulators designed for the
gas and pressure used. All hoses, fittings, etc.
should be suitable for the application and maintained in good
condition.
ELECTRIC AND MAGNETIC FIELDS
may be dangerous
5.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
8.a. Electric current flowing through any con-
ductor causes localized Electric and Magnetic
Fields (EMF). Cutting or gouging current cre-
ates EMF fields around torch cables and cutting
machines.
5.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from plasma cutting or gouging, arc weld-
ing operations and any other source of heat, sparks,
or flame.
8.b. EMF fields may interfere with some pacemakers, so opera-
tors having a pacemaker should consult their physician
before cutting or gouging.
5.d. Never allow any part of the electrode, torch or any other
electrically “hot” parts to touch a cylinder.
8.c. Exposure to EMF fields during cutting or gouging may have
other health effects which are now not known.
5.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
8d. All operators should use the following procedures in order to
minimize exposure to EMF fields from the cutting or gouging
circuit:
5.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
8.d.1. Route the torch and work cables together - Secure
them with tape when possible.
5.g. Read and follow the instructions on compressed gas cylin-
ders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,”available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
8.d.2. Never coil the torch cable around your body.
8.d.3. Do not place your body between the torch and
work cables. If the torch cable is on your right side,
the work cable should also be on your right side.
FOR ELECTRICALLY
powered equipment.
8.d.4. Connect the work cable to the workpiece as close as
possible to the area being cut or gouged.
6.a. Turn off input power using the disconnect
switch at the fuse box before working on the
equipment.
8.d.5. Do not work next to cutting power source.
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
Electrical Code and the manufacturer’s recommendations.
Apr. ‘93
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NOTES
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SAFETY
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
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:
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on place
la masse sur la charpente de la construction ou d’autres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de lev-
age, câbles de grue, ou autres circuits. Cela peut provoquer
des risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
du corps.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du ray-
onnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan-
talons sans revers, et chaussures montantes.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
er à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
Mar. ‘93
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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!
Thank 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 is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Model Name & Number _____________________________________
Code & Serial Number _____________________________________
Date of Purchase _____________________________________
Whenever you request replacement parts for or information on this equipment always supply the information
you have recorded above.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
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vi
TABLE OF CONTENTS
Page
Installation.......................................................................................................................Section A
Technical Specifications.......................................................................................................A-1
Safety Precautions ...............................................................................................................A-2
Select Proper Location.........................................................................................................A-2
Stacking................................................................................................................................A-2
Lifting and Moving ................................................................................................................A-2
Tilting....................................................................................................................................A-2
High Frequency Interference Protection...............................................................................A-2
Input Electrical Connections.................................................................................................A-3
Input Power Cord Connector Installation..............................................................................A-3
Frame Grounding .................................................................................................................A-3
Gas Input Connections.........................................................................................................A-4
Output Connections..............................................................................................................A-4
Torch Connection..........................................................................................................A-4
Operation.........................................................................................................................Section B
Safety Precautions ...............................................................................................................B-1
Description ...........................................................................................................................B-1
Preheat Temperature for Plasma Cutting.............................................................................B-1
User Responsibility...............................................................................................................B-2
Recommended Processes and Equipment..........................................................................B-2
Operational Features and Controls ......................................................................................B-2
Design Features and Advantages........................................................................................B-2
Cutting Capability .................................................................................................................B-3
Consumable Life ..................................................................................................................B-3
Limitations ............................................................................................................................B-4
Controls and Settings...........................................................................................................B-4
Pilot Arc Discussion..............................................................................................................B-6
Procedure Recommendations..............................................................................................B-6
General .........................................................................................................................B-6
Thin Gauge Sheet Metal ...............................................................................................B-6
Thick Sections of Metal.................................................................................................B-6
Suggestions for Extra Utility from the PRO-CUT System .............................................B-7
Accessories.....................................................................................................Section C
Genuine Lincoln Parts ...........................................................................................C-1
General Options / Accessories..............................................................................C-1
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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 Maintenance............................................................................................D-2
Troubleshooting..............................................................................................Section E
Safety Precautions.................................................................................................E-1
How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide ..........................................................................................E-2
Wiring Diagrams..............................................................................................Section F
Wiring Diagram ......................................................................................................F-1
Dimension Print......................................................................................................F-2
Parts List .....................................................................................P309 Series & P210-K
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A-1
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS - PRO-CUT 55
INPUT - SINGLE or THREE PHASE / 60 HERTZ ONLY
3Ø Input Current at Rated Output
Standard Voltage
1Ø Input Current at Rated Output
230/460/1 or 3Ø/60 Hz
230V: 55A @ 50%, 40A @ 100% 230V: 28A @ 50%, 21A @ 100%
460V: 30A @ 50%, 23A @ 100% 460V: 17A @ 50%, 15A @ 100%
Idle Current: 0.42 Amps, Idle Power 98 Watts
@ 230V
RATED OUTPUT
Duty Cycle
AMPS
50% Duty Cycle
100% Duty Cycle
55
40
OUTPUT
Current
Range
Open Circuit
Pilot Current
Voltage
MAX
18 Amps @ 100% Duty Cycle
335 VDC
25-55 Amps
REQUIRED GAS FLOW RATE
REQUIRED GAS INLET PRESSURE
70 PSI @ 360 SCFH
80 to 150 PSI
( 4.8 Bar. @ 10160 LHR)
( 5.4 Bar. TO 10.2 Bar.)
RECOMMEND INPUT WIRE AND FUSE SIZES
For all plasma cutting applications
Based on U.S. National Electrical Code
o
Ambient Temperature 30 C or Less
o
AC Input
Voltage at
60 Hertz
Fuse
Type 75 C
(Super Lag)
Circuit Breaker
(Delay Type)
Copper Wire in Conduit AWG (IEC) Sizes
Ground Wire
Input Supply Wire
2
2
1Ø - 230
1Ø - 460
70 AMPS
40 AMPS
#8 (8.4mm )
#10 (5.3mm )
2
2
#8 (8.4mm )
#10 (5.3mm )
2
2
3Ø - 230
3Ø - 460
40 AMPS
20 AMPS
#10 (5.3mm )
#10 (5.3mm )
2
2
#10 (5.3mm )
#10 (5.3mm )
PHYSICAL DIMENSIONS
Weight
Height
Width
Depth
Including Machine
Torch Cable (Length)
(25ft/7.6m) (50ft/15.2m)
12.6 in.
320 mm
11.0 in.
280 mm
26.0 in.
660 mm
70 lbs.
32 kg.
85 lbs.
39 kg.
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A-2
A-2
INSTALLATION
Read entire Installation Section before installing the
PRO-CUT 55.
LIFTING AND MOVING
Either the front or rear handles or both may be used to
lift or move the machine.
SAFETY PRECAUTIONS
WARNING
DO NOT use the pull handle on the optional undercar-
riage, if installed, to lift the machine. This handle is not
designed to support the full weight of the machine and
using it to lift the machine could cause personal injury
or damage to the machine.
ELECTRIC SHOCK CAN KILL.
•
Only qualified personnel
should install this machine.
TILTING
•
Turn the input power OFF
at the disconnect switch or
fuse box and discharge input
capacitors before working
inside the equipment.
The PRO-CUT 55 must be placed on a stable, level
surface so it will not topple over.
HIGH FREQUENCY INTERFERENCE
PROTECTION
•
•
Do not touch electrically hot parts.
The Pro-Cut 55 employs a touch start mechanism for
arc initiation which eliminates high frequency emis-
sions from the machine as compared with spark gap
and solid state type high frequency generators. Keep
in mind, though, that these machines may be used in
an environment where other high frequency generat-
ing machines are operating. By taking the following
steps, high frequency interference into the Pro-Cut
can be minimized
Always connect the PRO-CUT 55 ground-
ing terminal (located on the side of the
Case Back Assembly) to a good electrical
earth ground.
•
Turn the PRO-CUT Power Switch OFF
when connecting power cord to input
power.
___________________________________________
(1) Make sure the power supply chassis is connected
to a good earth ground. The work terminal ground
does NOT ground the machine frame.
SELECT PROPER LOCATION
Place the Pro-Cut 55 where clean cool air can freely
circulate in through the rear louvers and out through
the front/bottom opening. Dirt, dust or any foreign
material that can be drawn into the machine should be
kept at a minimum. Failure to observe these precau-
tions can result in excessive operating temperatures
and nuisance shutdown of the machine.
(2) Keep the work ground clamp isolated from other
work clamps that have high frequency.
(3) If the ground clamp cannot be isolated, then keep
the clamp as far as possible from other work
clamp connections.
A source of clean, dry air or nitrogen must be supplied
to the Pro-Cut 55. Oil in the air is a severe problem
and must be avoided. The supply pressure must be
between 80 and 150 psi. The flow rate is approximate-
ly 6.0 cfm (170 l/min.). Failure to observe these pre-
cautions could result in excessive operating tempera-
tures or damage to the torch.
(4) When the machine is enclosed in a metal building,
several good earth driven electrical grounds
around the periphery of the building are recom-
mended.
Failure to observe these recommended installation
procedures may cause improper function of the Pro-
Cut or possibly even damage to the control system or
power supply components.
STACKING
The PRO-CUT 55 cannot be stacked.
PRO-CUT 55
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A-3
A-3
INSTALLATION
INPUT ELECTRICAL
CONNECTIONS
INPUT POWER CORD CONNECTOR
INSTALLATION
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 Pro-Cut 55 is supplied with one 11' #8 AWG 3
lead input power cord already connected to the
machine. A cord connector provides a strain relief for
the input power cord as it passes through the left rear
access hole. The cord connector is designed for a
cord diameter of .40 - 1.03 in (10.2 - 26.2mm) if it
becomes necessary to install a different input cord.
a. The Pro-Cut 55 should be connected only by a
qualified electrician. Installation should be made in
accordance with the U.S. National Electrical Code,
all local codes and the information detailed below.
For three phase connection: Replace input power cord
with a #10 AWG 4 lead cable.
b. When received directly from the factory, the
machines are internally connected for 230 VAC.
Re-connection will be necessary if a higher input
voltage is used. To reconnect the Pro-Cut to 460
VAC or to connect back to 230 VAC, follow the
directions as outlined below. Follow this procedure
ONLY while the Pro-Cut is disconnected from the
input power and the capacitors have properly dis-
charged.
1. Connect leads of input power cord to a fused
power panel. Make sure the green lead is con-
nected to the panel and the panel is connected to
a good earth ground.
Install in accordance with all local and national electric
codes.
1. Open the access door on the side of the
machine.
FRAME GROUNDING
The frame of the Pro-Cut 55 must be properly ground-
ed. A ground terminal 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 con-
nected to this ground terminal. See the National
Electric Code for details on proper grounding meth-
ods. Install in accordance with all local and national
electrical codes.
2. For 200 to 230 : Position the large switch
to 200-230.
For 400 to 460 : Position the large switch
to 400-460.
3. Move the "A" lead to the appropriate termi-
nal.
PRO-CUT 55
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A-4
A-4
INSTALLATION
• While it is recommended that an in line prefilter be
placed ahead of each PRO-CUT that may be
installed in a shared air supply line, one large inline
prefilter may be used to accommodate several PRO-
CUTs simultaneously. If a shared prefilter is desired,
it must be rated to provide the necessary flow rate,
as specified, to ensure proper operation of each of
the PRO-CUTs sharing a connection.
GAS INPUT CONNECTIONS
Supply the PRO-CUT 55 with clean compressed air or
nitrogen.
•
•
Supply pressure must be between 80 psi
and 150 psi.
Flow rate should be approximately 6.0
cfm (170 I/min.).
NOTE: When using nitrogen gas from a cylinder, the
cylinder must have a pressure regulator.
NOTE: Oil in the air supply to the PRO-CUT 55 can
cause severe problems. Use only a clean air
supply.
•
•
Maximum psi from nitrogen gas cylinder to
PRO-CUT 55 regulator should never
exceed 150 psi.
•
•
Connect the gas supply to the PRO-CUT 55
regulator.
Install a hose between the nitrogen gas
cylinder regulator and the PRO-CUT 55
gas inlet.
Compressed gas should be supplied to the fit-
ting connection mounted on the filter at the
rear of the machine. If necessary, this fitting
can be removed allowing plumbing access
through the 1/4” NPT input port on the filter
body.
WARNING
CYLINDER could explode if damaged.
• Keep cylinder upright and chained to a
fixed support.
• If compressed air is being used, it is highly recom-
mended that an inline prefilter be installed in the air
supply line ahead of the air connection to the PRO-
CUT’s coalescing filter. While the coalescing filter is
used to remove small amounts of oil and water
aerosol particles from the air supply line, the prefilter
can be used to remove larger particulates before
they reach the coalescing filter element.This will pro-
long the life of the coalescing filter element by up to
six times what it would be without the prefilter, and in
turn, prolong the life of the PRO-CUT torch and con-
sumables as well.
• Keep cylinder away from areas where it
could be damaged.
• Never lift machine with cylinder attached.
•
•
•
Never allow the cutting torch to touch the
cylinder.
Keep cylinder away from live electrical
parts.
Maximum inlet pressure 150 psi.
• A standard nominal 5 micron inline prefilter is recom-
mended; however, for optimum performance, select
a prefilter with a 3 micron absolute rating. If these fil-
ter ratings are unavailable, anything with a rating
less than, or equal to, 20 micron would be accept-
able to use. In line filter elements will generally filter
the air with little restriction to the airflow until the ele-
ment is about 75 % contaminated. After this point,
there will be a noticeable pressure drop in the line.
Filter elements should be replaced when a pressure
drop of 8-10 psi is indicated; however, for optimum
performance of the PRO-CUT, the filter element
should be replaced at or before the pressure drop
reaches 8 psi. Be sure to select a prefilter that will
accommodate the necessary flow rating for the
PRO-CUT as specified in the Installation section of
this instruction manual under the Gas Input
Connections heading.
__________________
OUTPUT CONNECTIONS
Torch Connection
The Pro-Cut 55 is sent from the factory with a PCT 80
cutting torch. Additional cutting torches can be
ordered from the K1571 series. Hand-held and mech-
anized torches come with 25' or 50’ cables.
All torches are connected to the Pro-Cut with a quick
connect at the bulkhead for easy change over. This
feature is excellent for changing between a hand cut-
ting torch and a mechanized torch. This feature is also
handy for troubleshooting.
For more information on the torch and its components,
refer to the PCT80 Operator’s Manual (IM588 latest
version).
PRO-CUT 55
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B-1
B-1
OPERATION
Read and understand this entire section before oper-
ating the machine.
DESCRIPTION
The Pro-Cut 55 is a constant current, continuous con-
trol plasma cutting power source. It provides superior
and reliable starting characteristics, cutting visibility
and arc stability. When cutting expanded metal, the
Pro-Cut 55 out performs the competition due to its
quick, clean response to arc transfers. The power
supply design provides high transfer-to-cut distances
which makes pierce cutting more reliable and with
less nozzle wear. The control system has a safety
mechanism to insure that the nozzle and electrode are
in place before cutting or gouging. This is extremely
important due to the high voltages involved.
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK
can kill.
• Do not touch electrically live parts
or electrode with skin or wet
clothing.
• Insulate yourself from work and
ground.
The Pro-Cut 55 comes standard with an air regulator,
coarse air filter, and pressure gauge. The machine
also comes with an 11' input power cord. There are
four different torch and cable systems to choose from:
hand-held torch with 25' or 50' cable, machine and
robotic torch both with 25' and 50' cable.
Consumables are included with each Pro-Cut pur-
chase so that cutting can begin right out of the box.
Consumables can also be ordered as individual pack-
ages. An undercarriage kit can also be ordered sepa-
rately.
• 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.
WELDING, CUTTING and
GOUGING SPARKS
The Pro-Cut 55 initiates the plasma arc with a simple,
yet reliable, touch start mechanism. This system elimi-
nates many of the failure problems associated with hi-
frequency start systems. The Pro-Cut 55 is capable of
cutting with nitrogen or air. Nitrogen is used to cut alu-
minum and other nonferrous metals.
can cause fire or explosion
• Keep flammable material away.
• Do not weld, cut or gouge on
containers that have held combustibles.
The Pro-Cut 55 is controlled by a microprocessor-
based control board. The machine performs rudimen-
tary self troubleshooting when powered up which aids
in field servicing.
ARC RAYS
can burn.
• Wear eye, ear and body
protection.
PREHEAT TEMPERATURE FOR
PLASMA CUTTING
PLASMA ARC
can injure
Preheat temperature control is not necessary in most
applications when plasma arc cutting or gouging.
Preheat temperature control may be necessary on high
carbon alloy steels and heat treated aluminum for crack
resistance and hardness control. Job conditions, pre-
vailing codes, alloy level, and other considerations may
also require preheat temperature control. The following
minimum preheat temperature is recommended as a
starting point. Higher temperatures may be used as
required by the job conditions and/or prevailing codes.
If cracking or excessive hardness occurs on the cut
face, higher preheat temperature may be required. The
recommended minimum preheat temperature for plate
thickness up to 1/2" (12.7mm) is 70°F (21.1°C).
• Keep your body away from nozzle
and plasma arc.
• Operate the pilot arc with caution. The
pilot arc is capable of burning the
operator, others or even piercing
safety clothing.
Observe additional Safety Guidelines detailed in
the beginning of this manual.
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B-2
B-2
OPERATION
- Input over voltage protection.
USER RESPONSIBILITY
- Bright 3.0 second timed pilot arc.
- Purge momentary push button.
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, quench, gas type, gas flow
rate and equipment may produce results different than
those expected. Some adjustments to procedures
may be necessary to compensate for unique individ-
ual conditions. Test all procedures duplicating actual
field conditions.
- Air regulator and pressure gage located on the front
of machine for convenience.
- Parts-in-Place mechanism to detect proper installa-
tion of consumables and torch.
- Latching Parts-in-Place mechanism. Requires a
positive operator reset.
RECOMMENDED PROCESSES AND
EQUIPMENT
- Automatic detection of faulty output control.
- In line coarse air filter.
The PRO-CUT 55 is capable of all cutting and goug-
ing applications within its output capacity of 25 to 55
amps. These applications include thin gage sheet
metal and expanded metal.
- Preflow/Postflow timing. Preflow is eliminated if arc
is re-initiated in Postflow.
- Thermostatic Protection.
OPERATIONAL FEATURES AND
CONTROLS
- Solid state over-current protection.
- Works with pure nitrogen for cutting nonferrous
materials.
The PRO-CUT 55 comes with an ON/OFF POWER
SWITCH, OUTPUT CURRENT CONTROL, PURGE
BUTTON and a SAFETY RESET BUTTON.
- Reconnectable for 230 VAC or 460 VAC inputs.
- Quick disconnect torch.
DESIGN FEATURES AND
ADVANTAGES
- Dead front display for machine status.
The microprocessor controlled PRO-CUT 55 design
makes plasma cutting and gouging tasks uncomplicat-
ed. This list of design features and advantages will
help you understand the machine's total capabilities
so that you can get maximum use from your machine.
- Unique electrode and Vortech™ nozzle design for
optimum cooling and long life.
- Swirl texture inside Vortech™ nozzle for better start-
ing reliability and higher quality cuts.
- Unique drag cup design for durability and elimina-
tion of double arcing.
- Light weight and portable design for industrial use.
- Continuous control, 25 - 55 amps.
- Reliable touch start mechanism for plasma arc initi-
ation.
- Unique microprocessor controlled starting sequence
for safe and consistent starting.
- Rapid arc transfer for fast cutting of expanded
metal.
- High transfer distance for ease of use.
- Soft start of input filter capacitors at start up.
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B-3
B-3
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". Example: 0.25” material may be cut at a setting of 35 amps at an
approximate speed of 38 IPM or at a setting of 45 amps at an approximate speed of 57 IPM or at a setting of 55
amps at an approximate speed of 62 IPM.
Lincoln's PRO-CUT 55
Mild Steel Cut Capacity Chart
100
80
60
40
20
25 A
45 A
0.625
55 A
0.750
35 A
0.500
0
0.000
0.125
0.250
0.375
Material Thickness
Figure B.1
CONSUMABLE LIFE
The expected life for the Pro-Cut 55's electrode under normal operating conditions is approximately 320
starts/cuts. An erosion of .060" is typical for end of electrode life, however, the electrode life may last longer. A
green and erratic arc will indicate definite electrode failure and the electrode should be replaced immediately.
It is recommended that consumables be replaced in complete sets. (Example: Electrode and Nozzle). This will
maximize the performance of the PRO-CUT system.
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B-4
B-4
OPERATION
kerf (cut) width, heat affected zone or travel speed
as required.
LIMITATIONS
Do not exceed output current and duty cycle rating of
machine. Do not use the PRO-CUT 55 for pipe thaw-
ing.
• 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.
- Adjust the gas regulator for 70 PSI for 25’ torch-
es or 75 PSI for 50’ torches.
- Release the Purge button.
CONTROLS AND SETTINGS
- The gas will immediately turn off. The pressure
gage 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.
Gas
Purge
Button
Status
Board
Indicators
Reset
Button
Gas
Regulator
Gauge
• When ready to cut, place the torch near the work,
make certain all safety precautions have been taken
and pull the trigger.
XXXX XXXX XXXX XXXX
Gas
Regulator
Knob
Output
Control
Knob
- 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 and the pilot arc will start immediate-
ly.)
- The pilot arc will run for 3.0 seconds and shut off
unless the arc is brought in contact with the work
and the arc is transferred. Avoid excessive pilot
arc time by transferring the arc to the workpiece
quickly to improve parts life.
- When the arc is brought within 1/4" from the
work piece: the arc will transfer, the current will
ramp up to the setting on the control panel, and
the cut can last indefinitely (or until the duty
cycle of the Pro-Cut is exceeded). Do not touch
the nozzle to the work when cutting with the
control panel setting above mid range or dam-
age to the consumables will result.
PRO-CUT 55
Consumable
Storage
(behind
door)
OFF
Input
Power
Switch
Torch
Connector
Work
Cable
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 is important to follow
these operating steps each time you use the machine.
• Pierce the work piece by slowly lowering the torch
onto the metal at a 300 angle away from the opera-
tor. This will blow the dross away from the torch tip.
Slowly rotate the torch to vertical position as the arc
becomes deeper.
• Turn the machine's ON/OFF POWER SWITCH to
OFF position.
• Connect the air supply to the machine.
• Turn the main power and the machine power switch
on.
TORCH AT 300 ANGLE
TO PIERCE
- The fan should start.
- The pre-charge circuit will operate for 3 seconds,
then the green "Power" LED should turn on.
- If the "SAFETY" LED is lit, push the "Reset" but-
ton. If there is no problem, the LED will go off. If
there is a problem, refer to Step "SAFETY LED"
in this section.
ROTATE TO
900 ANGLE TO CUT
300
900
VERTICAAL ANGLE
FOR CUTTTING
• Be sure that the work lead is clamped to the work-
piece before cutting.
CUT
• Set the output current control knob at maximum
position for high cutting speed and less dross forma-
tion. Reduce the current, if desired to reduce the
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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 torch nozzle touch the work or carry a long
arc.
TORCH HELD AT
450 ANGLE
THROUGHOUT GOUGE
• 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.
ANGLE
MAINTAINED
THROUGHOUT
GOUGE
5° - 15° Leading Angle
• If the "SAFETY" LED lights at any time, check the
following:
• Check the assembly of the torch consumables. If
Direction of Travel
WARNING
ELECTRIC SHOCK CAN KILL.
• Turn off machine at the disconnect
switch on the front of the machine
before tightening, cleaning or replacing
consumables.
10° - 20°
Arc Lag
• Use a 5° - 15° leading angle in the direction of the
cut.
----------------------------------------------------------------------------
they are not properly in place, the machine will not
start. Make sure that the shield cup is hand tight.
Do not use pliers or over tighten.
• Use the drag cup to maintain constant standoff for
better cut quality and to protect the nozzle from spat-
ter.
• Check the conditions of the inside of the nozzle. If
debris has collected, rub the electrode on the inside
bottom of the nozzle to remove any oxide layer that
may have built up. Refer to "Suggestions for Extra
Utility from the PRO-CUT system".
• Use the drag cup with a metal template to prevent
nozzle double arcing.
• Finish the cut to be made and release the trigger.
• When the trigger is released, the arc will stop.
• Check the condition of the electrode. If the end has
a crater-like appearance, replace it along with the
nozzle. The maximum wear depth of the electrode is
approximately .062”. A green and erratic arc will
indicate definite electrode failure and the electrode
should be replaced immediately.
- The gas will continue to flow for 10 seconds of
postflow. If the trigger is activated within this time
period, the pilot arc will immediately restart.
• If the dross is difficult to remove, reduce the cutting
speed. High speed dross is more difficult to remove
than low speed dross.
• Replace the nozzle when the orifice exit is eroded
away or oval shaped.
• The right side of the cut is more square than the left
as viewed along the direction of travel.
• After the problem is found, or if there is nothing
apparently wrong, reset the machine by pressing
the "Reset" button. (It is possible for electrical noise
to trip the safety circuit on rare occasions. This
should not be a regular occurrence.)
• Tilt the torch about 45° from the workpiece and hold
the nozzle 1/8” (3.2mm) to 3/16” (4.7mm) above the
workpiece for gouging.
• If the machine does not reset or continues to trip,
consult the Troubleshooting Section.
• Clean spatter and scale from the nozzle and drag
cup frequently.
• Use the proper cutting or gouging procedures
referred to in Procedure Recommendations.
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B-6
B-6
OPERATION
Thick Sections of Metal
PILOT ARC DISCUSSION
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
rapid succession, is not recommended as these starts
will generally reduce consumable life. Occasionally,
the pilot arc may sputter or start intermittently. This is
aggravated when the consumables are worn or the air
pressure is too high. Always keep in mind that the
pilot arc is designed to transfer the arc to the work-
piece and not for numerous starts without cutting.
Torch Standoff
Machine Output Setting
1/8" thru 3/16"
Standoff
Output Setting
Mid. thru Max. Range
When the pilot arc is started, a slight impulse will be
felt in the torch handle. This occurrence is normal and
is the mechanism which starts the plasma arc. This
impulse can also be used to help troubleshoot a "no
start" condition.
Output set above mid-range.
• The best quality and consumable life will be
obtained by holding the torch off the surface
about 3/16". Too long an arc may compromise
cut quality and consumable life. The nozzle
should NOT be dragged on the work.
PROCEDURE RECOMMENDATIONS
When properly used, plasma arc cutting or gouging is
a very economical process. Improper use will result in
a very high operating cost.
• Use of the S22151 Drag Cup will maintain the
proper standoff. The only reason not to use the
Drag Cup when the output control is set above
mid-range is in special, tight corners. Always
hold at least a 1/8" standoff in those situations.
General - In All Cases
• If piercing is required, slowly lower the torch at
an angle of about 30° to blow the dross away
from the torch tip and slowly rotate the torch to
a vertical position as the arc becomes deeper.
This process will blow a lot of molten metal and
dross. Be careful! Blow the dross away from
the torch, the operator and any flammable
objects.
• Follow safety precautions as printed throughout
this operating manual and on the machine.
Thin Gauge Sheet Metal:
Torch Standoff
Machine Output Setting
• Where possible, start the cut from the edge of
the work piece.
• Keep moving! A steady speed is necessary.
Do not pause.
• Do not allow torch cable or body to contact hot
surface.
DRAG thru 1/16"
Standoff
Output Setting
Min. thru Mid. Range
Output set below mid-range.
• The nozzle may be dragged on the metal sur-
face, touching it lightly to the surface after pierc-
ing a hole. Current control should be set below
the mid range.
• Do not allow cable or body to contact hot sur-
face.
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B-7
B-7
OPERATION
h. Set air pressure to recommended setting. A
higher or lower pressure will cause turbulence
in the plasma arc, eroding the orifice of the
nozzle tip.
Suggestions for Extra Utility from the
PRO-CUT System:
WARNING
ELECTRIC SHOCK CAN KILL.
• Turn off machine at the disconnect
switch on the front of the machine
before tightening, cleaning or replacing
consumables.
i. Use only Lincoln consumable parts. These
parts are patented and using any other
replacement consumables may cause damage
to the torch or reduce cut quality.
----------------------------------------------------------------------------
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 Pro-Cut's safety circuit. When
this happens turn the power off, remove the nozzle
and electrode and use the electrode to rub against
the inside bottom surface of the nozzle. This will
help remove any oxide buildup. Replace the noz-
zle, turn on the power and continue cutting. If the
Parts-in-Place circuit continues to trip after clean-
ing the consumables, then replace them with a
new set. Do not continue to try and cut with exces-
sively worn consumables as this can cause dam-
age to the torch head and will degrade cut quality.
2. To improve consumable life, here are some sug-
gestions that may be useful:
a. Never drag the nozzle on the work surface if
the output control knob is above the mid range
setting.
b. Make sure the air supply to the Pro-Cut is
clean and free of oil. Use several extra in line
filters if necessary.
c. Use the lowest output setting possible to make
a good quality cut at the desired cut speed.
d. Minimize dross buildup on the nozzle tip by
starting the cut from the edge of the plate
when possible.
e. Pierce cutting should be done only when nec-
essary. If piercing, angle torch about 30° from
the plane perpendicular to the work piece,
transfer the arc, then bring the torch perpen-
dicular to the work and begin parallel move-
ment.
f. Reduce the number of pilot arc starts without
transferring to the work.
g. Reduce the pilot arc time before transferring
to the work.
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C-1
C-1
ACCESSORIES
ALWAYS USE GENUINE LINCOLN GENERAL OPTIONS /
ELECTRIC ELECTRODES AND ACCESSORIES
VORTECH™ NOZZLES
The following options/accessories are available for
your PRO-CUT 55 from your local Lincoln Distributor.
• Only Genuine Lincoln Electric consumables yield
the best cutting performance for the PRO-CUT 55.
K1600-1 Undercarriage - A valet style undercarriage
with pull-out handle for machine only. Provides Torch
and Work Cable storage.
• The patented VORTECH™ nozzle provides an
extra “kick” of swirl as the arc exits the nozzle which
S22147-043 - VORTECH™ nozzle with an .043” (1.2
mm) Orifice
improves cutting performance. No other nozzle has
this capability or can match its performance.
S22147-068 - VORTECH™ nozzle with an .068” (1.7
mm) Orifice
S22149 - Electrode - replacement electrodes for cut-
ting.
S22150 - Shield Cup - This shields the torch tip and
provides more visibility to the workpiece than the drag
cup. Note the shield cup does not prevent the torch tip
from touching the workpiece.
S22151 - Drag Cup - The drag cup protects the torch
by preventing the torch from touching the workpiece.
K1571 Series - PCT 80 Torches come in 25’ and 50’
lengths in either hand held or mechanized versions.
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D-1
D-1
MAINTENANCE
4. Obtain a high resistance and high wattage resistor
(25-1000 ohms and 25 watts minimum). This resis-
tor is not supplied with machine. NEVER USE A
SHORTING STRAP FOR THIS PROCEDURE.
WARNING
ELECTRIC SHOCK can kill.
• Have an electrician install and service
this equipment.
• Turn the input power off at the fuse
box before working on equipment.
• Do not touch electrically hot parts.
• Prior to Performing preventative main-
tenance, perform the following capaci-
tor discharge procedure to avoid elec-
tric shock.
5. Locate the two capacitor terminals (large hex head
cap screws) on the top and bottom of the Power
P.C. Board shown in Figure D.1.
6. Use electrically insulated gloves and insulated pli-
ers. Hold body of the resistor and connect resistor
leads across the two capacitor terminals. Hold
resistor in place for 10 seconds. DO NOT TOUCH
CAPACITOR TERMINALS WITH YOUR BARE
HANDS.
---------------------------------------------------------------------
INPUT FILTER CAPACITOR
DISCHARGE PROCEDURE
1. Turn off input power or disconnect input power
lines.
7. Repeat discharge procedure for the other capaci-
tor .
2. Remove the 5/16" hex head screws from the side
and top of the machine and remove wrap-around
machine cover.
8. Check voltage across terminals of all capacitors
with a DC voltmeter. Polarity of capacitor terminals
is marked on PC board above terminals. Voltage
should be zero. If any voltage remains, repeat this
capacitor discharge procedure.
3. Be careful not to make contact with the capacitor
terminals that are located on the top and bottom of
the Power Board on the right side of the machine.
FIGURE D.1 — LOCATION OF INPUT FILTER CAPACITOR TERMINALS.
POWER
BOARD
UPPER
CAPACITOR TERMINALS
LOWER
CAPACITOR
TERMINALS
POWER
RESISTOR
INSULATED
PLIERS
RIGHT SIDE OF MACHINE
INSULATED
GLOVES
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D-2
D-2
MAINTENANCE
ROUTINE MAINTENANCE
PERIODIC 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.
WARNING
ELECTRIC SHOCK CAN KILL.
• Turn off machine at the disconnect
switch on the front of the machine
before tightening, cleaning or replacing
consumables.
----------------------------------------------------------------------------
2. Every 6 months or so, the machine should be
cleaned with a low pressure airstream. Keeping the
machine clean will result in cooler operation and
higher reliability. Be sure to clean these areas:
Change consumables as required.
1. Thermal Protection
- Power, Output and Control printed circuit
boards and heat sinks
- Power switch
- Main Transformer
- Input Rectifier
Two thermostats protect the machine from excessive
operating temperatures. Excessive temperatures may
be caused by a lack of cooling air or operating the
machine beyond the duty cycle and output rating. If
excessive operating temperatures should occur, the
yellow thermal LED will light and the thermostat will
prevent output voltage or current.
3. Examine the sheet metal case for dents or break-
age. Repair the case as required. Keep the case in
good condition to insure that high voltage parts are
protected and correct spacings are maintained. All
external sheet metal screws must be in place to
insure case strength and electrical ground continu-
ity.
Thermostats are self-resetting once the machine cools
sufficiently. If the thermostat shutdown was caused by
excessive output or duty cycle and the fan is operating
normally, the Power Switch may be left on and the
reset should occur within a 15 minute period. If the fan
is not turning or the air intake louvers were obstructed,
then the power must be switched off and the fan prob-
lem or air obstruction must be corrected.
4. Check the air regulator filter to be sure it does not
become clogged. The air filter on the machine is
self draining and will not have to be emptied.
5. Check the filter element every several months to
see if it is clogged (weekly in very dirty environ-
ments). Replace if necessary by first removing the
two screws that attach the filter cage to the back
panel assembly, then slide the cage away from the
back of the machine and remove. Next, twist the
clear filter bowl until it comes off (be careful not to
lose the o-ring seated at the top of the bowl
threads). Unscrew the filter element and replace
with new element. Assemble parts in reverse order
as described above.
2. Filter Capacitor Conditioning (Pro-Cut 55, 400-460
VAC only)
A protection circuit is included to monitor the voltage
across filter capacitors C1 and C2. In the event that
the capacitor voltage is too high, the protection circuit
will prevent output. The protection circuit may prevent
output providing all these circumstances are met:
a. Machine is connected for 400-460 VAC input.
b. Machine did not have power applied for many
months.
c. Machine will not produce output when power is
first switched on.
6. Inspect the cable periodically for any slits or punc-
ture marks in the cable jacket. Replace if neces-
sary. Check to make sure that nothing is crushing
the cable and blocking the flow of air through the
air tube inside. Also, check for kinks in the cable
periodically and relieve any so as not to restrict the
flow of air to the torch.
If these circumstances apply, the proper action is to
switch the machine on and let it idle for up to 30 min-
utes. This is required to condition the filter capacitors
after an extended storage time. The protection circuit
will automatically reset once the capacitor conditioning
and resultant voltage levels are acceptable. It may be
necessary to turn the power switch off and back on
again after this period.
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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.
__________________________________________________________________________
This Troubleshooting Guide is provided to
help you locate and repair possible machine
malfunctions. Simply follow the three-step
procedure listed below.
Step 3. RECOMMENDED COURSE OF
ACTION
This column provides a course of action for
the Possible Cause, generally it states to
contact you local Lincoln Authorized Field
Service Facility.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM
(SYMPTOMS)”. This column describes
possible symptoms that the machine may
exhibit. Find the listing that best describes
the symptom that the machine is exhibiting.
If you do not understand or are unable to
perform the Recommended Course of
Action safely, contact you local Lincoln
Authorized Field Service Facility.
Step 2. POSSIBLE CAUSE.
The second column labeled “POSSIBLE
CAUSE” lists the obvious external possibili-
ties that may contribute to the machine
symptom.
WARNING
ELECTRIC SHOCK CAN KILL.
• Turn off machine at the disconnect
switch on the front of the machine and
remove main power supply connec-
tions before doing any troubleshooting.
----------------------------------------------------------------------------
CAUTION
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.
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E-2
E-2
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
RECOMMENDED
COURSE OF ACTION
No Status indicators light and the fan 1. Check the input power to be sure
does not operate 5 seconds after the it is on.
power switch is turned on.
2. Check the power line fuses and
machine connection.
3. Disconnect input power at fuse
panel and check line switch conti-
nuity. Replace line switch if bad.
4. Auxiliary transformer may be
faulty.
No Status indicators light 5 seconds 1. Auxiliary transformer may be
after the power switch is turned on, faulty.
but the fan operates.
2. Disconnect input power from the
machine. Check that connectors
on harness between Control Bd.
and Display Bd. are properly seat-
ed.
If all recommended possible areas of
misadjustment have been checked
and the problem persists, Contact
your local Lincoln Authorized
Field Service Facility.
3. Possible faulty Control Board.
All Status indicators remain lit imme- 1. The microprocessor has experi-
diately after power up.
enced a memory fault. Consult
local Lincoln Field Service shop.
All Status indicators begin to blink 1. Turn power off. Make sure recon-
within 5 seconds after power up.
nect is positioned correctly for the
input voltage used. Wait at least 1
minute after power down before
re-connecting the machine.
Reconnect machine,then restore
power to Pro-Cut.
2. Possible faulty Primary board.
3. Possible faulty Control board.
CAUTION
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.
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E-3
E-3
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
RECOMMENDED
COURSE OF ACTION
The Pro-Cut powers up properly but 1. Press Purge button on the front of
there is no response when the trig- the Pro-Cut. If air does not flow,
ger is pulled and only the POWER then:
LED is lit.
a. Auxiliary transformer may be
faulty.
b. The main gas solenoid assem-
bly may be faulty. Check or
replace.
c. Possible faulty Output Power
board.
d. Possible faulty Control board.
2. (check for continuity from the bulk-
head connector to the molex) See
Wiring Diagram.
3. Remove the handles (or barrel) of
the torch and examine all the con-
nections. Pay attention to location
of electrode lead mounting at back
of torch head, broken trigger and
solenoid leads.
If all recommended possible areas of
misadjustment have been checked
and the problem persists, Contact
your local Lincoln Authorized
Field Service Facility.
4. Check for proper trigger switch
operation. Remove the torch cable
assembly from the Pro Cut and
test for continuity between 9 and 1
at the quick connect when the trig-
ger switch is depressed and no
continuity when the switch is not
depressed. Replace the trigger
switch or torch cable if defective.
5. Possible faulty Control board.
6. Possible faulty Output Power
board.
CAUTION
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.
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E-4
E-4
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
RECOMMENDED
COURSE OF ACTION
When the trigger is pulled air begins 1. Check the torch consumables to be
to flow, but there is no pilot arc after
at least 3 seconds.
sure they are not dirty or greasy,
and are in good shape. Replace
the consumables if necessary.
2. Make sure the air pressure is set
at 70 psi.
3. Make sure there are no kinks or
restrictions for air flow in the torch
cable. Replace cable as needed.
4. If a slight thump cannot be felt in
the torch when the trigger is
pulled, check for loose connection
in the torch head and solenoid
assembly.
5. With machine turned off - input
power removed, and torch and
consumables connected - mea-
sure resistance on Output Power
board between B1 and B21. If
>10Ω, possible fault in torch and
cable assembly.
If all recommended possible areas of
misadjustment have been checked
and the problem persists, Contact
your local Lincoln Authorized
Field Service Facility.
6. Possible fault in Output board.
The air begins to flow and there is a 1. Check the torch consumables to
very brief arc that snaps out consis- be sure they are in tight, not dirty
tently with repeated trigger pulls.
or greasy and in good shape.
Replace if necessary.
2. Make sure the air pressure is set
at 70 psi.
3. Possible fault in Output Power board.
1. Check the torch consumables to be
sure they are in tight, not dirty or
greasy and in good shape. Replace if
necessary.
The arc starts but sputters badly.
2. Check air supply for oil or a great deal
of water. If there is oil or a great deal
of water, the air must be filtered or the
machine switched to nitrogen or bot-
tled air.
3. Make sure the air pressure is set at 70
psi.
CAUTION
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.
PRO-CUT 55
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E-5
E-5
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
RECOMMENDED
COURSE OF ACTION
Pilot arc starts but will not transfer 1. Check work lead connection for
when brought near work.
clean, secure connection.
2. Plasma will only cut conductive
material. Do not attempt to cut
fiberglass, plastic, rubber, PVC or
any other non-conductive material.
If all recommended possible areas of
misadjustment have been checked
and the problem persists, Contact
your local Lincoln Authorized
Field Service Facility.
3. Make sure work piece is clean
and dry. Remove any scale, rust
or dross.
4. Check all connections to Output
board.
5. Possible faulty Control board.
CAUTION
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.
PRO-CUT 55
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E-6
E-6
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
STATUS BOARD INDICATORS
SYMPTOM
CHECK
Machine is unresponsive immediately after 1. There is a 4 second soft start period for pre-charging the input fil-
power-up.
ter capacitors. Wait until that time is up. The Power LED will light
when ready. If not, refer to the first part of this section.
The Air Low LED is lit
1. Make sure there is at least 80 psi connected to the gas connec-
tion at the back of the machine.
2. Press the Purge button and set the regulator to 70 psi. The pres-
sure may increase when air stops flowing but this is normal. Do
not reset the pressure while the air is OFF.
3. Possible faulty Pressure Switch.
4. Possible faulty Control board.
The Safety LED is flashing
1. Make sure there is a Lincoln torch and cable assembly connect-
ed properly to the Pro-Cut bulk head connector.
2. Check consumables for proper installation or excessive wear.
Replace if excessively worn. If not, use a piece of fine emery
cloth to remove any oxide buildup on the tip of the electrode.
The Safety LED is lit and steady
The Thermal LED is lit
1. Press the Reset button. If torch and consumables are properly
installed, the Safety LED should turn off. Normal cutting or goug-
ing can resume.
1. The machine's thermostat has tripped due to exceeded duty
cycle limits. Do NOT turn the power off. Allow the machine to
cool for 15 - 30 minutes and the thermostat will reset itself.
2. The machine's air louvers or fans are obstructed such that air
cannot flow to properly cool the machine. Remove any foreign
material that may block air flow. Blow the machine out with a
clean, dry air stream.
3. Possible faulty Control board.
PRO-CUT 55
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F-1
ENHANCED DIAGRAMS
F-1
DIAGRAMS
F R O N T O F M A C H I N E
6 4
6 2
6 1
S
U T
S
F R - O
F R - I N
F R - I N
S
S
F R - O U T
B K - O U T
B K - I N
S
S
S
S
T
U
B K - I N
B K - O
@
9 / ( 6 ž 4 I @
xxxxxxx
ELEC
R E A R O F M A C H I N E
PRO-CUT 55
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F-2
F-2
DIAGRAMS
F R O N T O F M A C H I N E
6 4
6 2
6 1
- I N
F R
S
T
U
- O
S
F R
T
K - O U
B
K - I N
B
S
S
xxxxxxx
ELEC
R E A R O F M A C H I N E
PRO-CUT 55
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F-3
F-3
DIAGRAMS
PRO-CUT 55
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NOTES
PRO-CUT 55
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● Do not touch electrically live parts or
electrode with skin or wet clothing.
● Insulate yourself from work and
ground.
● Keep flammable materials away.
● Wear eye, ear and body protection.
WARNING
Spanish
● No toque las partes o los electrodos ● Mantenga el material combustible
● Protéjase los ojos, los oídos y el
bajo carga con la piel o ropa moja-
da.
● Aislese del trabajo y de la tierra.
fuera del área de trabajo.
cuerpo.
AVISO DE
PRECAUCION
French
● Ne laissez ni la peau ni des vête-
ments mouillés entrer en contact
avec des pièces sous tension.
● Gardez à l’écart de tout matériel
inflammable.
● Protégez vos yeux, vos oreilles et
votre corps.
ATTENTION
● Isolez-vous du travail et de la terre.
German
● Berühren Sie keine stromführenden
Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!
● Isolieren Sie sich von den
● Entfernen Sie brennbarres Material! ● Tragen Sie Augen-, Ohren- und Kör-
perschutz!
WARNUNG
Elektroden und dem Erdboden!
Portuguese
● Não toque partes elétricas e elec-
trodos com a pele ou roupa molha-
da.
● Mantenha inflamáveis bem guarda- ● Use proteção para a vista, ouvido e
dos.
corpo.
ATENÇÃO
● Isole-se da peça e terra.
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND 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 FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-
STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
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● Keep your head out of fumes.
● Use ventilation or exhaust to
remove fumes from breathing zone.
● Turn power off before servicing.
● Do not operate with panel open or
guards off.
WARNING
Spanish
● Los humos fuera de la zona de res-
piración.
● Mantenga la cabeza fuera de los
humos. Utilice ventilación o
aspiración para gases.
● Desconectar el cable de ali-
mentación de poder de la máquina
antes de iniciar cualquier servicio.
● No operar con panel abierto o
guardas quitadas.
AVISO DE
PRECAUCION
French
● Débranchez le courant avant l’entre- ● N’opérez pas avec les panneaux
tien.
● Gardez la tête à l’écart des fumées.
● Utilisez un ventilateur ou un aspira-
teur pour ôter les fumées des zones
de travail.
ouverts ou avec les dispositifs de
protection enlevés.
ATTENTION
German
● Strom vor Wartungsarbeiten
abschalten! (Netzstrom völlig öff-
nen; Maschine anhalten!)
● Anlage nie ohne Schutzgehäuse
oder Innenschutzverkleidung in
Betrieb setzen!
● Vermeiden Sie das Einatmen von
Schweibrauch!
● Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
WARNUNG
Portuguese
● Não opere com as tampas removidas.
● Desligue a corrente antes de fazer
serviço.
● Mantenha-se afastado das partes
moventes.
● Não opere com os paineis abertos
ou guardas removidas.
● Mantenha seu rosto da fumaça.
● Use ventilação e exhaustão para
remover fumo da zona respiratória.
ATENÇÃO
● Não toque as partes elétricas nuas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
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• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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