Lincoln Electric PRO-CUT 25 Manual de usuario

W83CE026

10/2000

Rev.1

PRO-CUTTM 25

OPERATOR’S MANUAL

MANUALE OPERATIVO

BEDIENUNGSANLEITUNG

MANUAL DE INSTRUCCIONES

MANUEL D'INSTRUCTIONS

BRUKSANVISNING OG DELELISTE

GEBRUIKSAANWIJZING

LINCOLN ELECTRIC ITALIA S.r.l

Via degli Artigiani 80, 17015 Celle Ligure (SV), Italia

www.lincolnelectric.com

Declaration of conformity

Dichiarazione di conformità

Konformitätserklärung

Declaración de conformidad

Déclaration de conformité

Samsvars erklæring

Verklaring van overeenstemming

LINCOLN ELECTRIC ITALIA S.r.l.

Declares that the plasma machine:

Dichiara che la macchina al plasma:

Erklärt, daß die Plasmaschneidanlage:

Declara que el equipo de corte por plasma:

Déclare que le poste pour coupage plasma:

Bekrefter at denne plasma skjæremaskinen:

Verklaart dat de volgende plasma machine:

PRO-CUT 25 s/n

conforms to the following directives:

è conforme alle seguenti direttive:

den folgenden Bestimmungen entspricht:

es conforme con las siguientes directivas:

Est conforme aux directives suivantes:

er i samsvar med følgende direktiver:

Overeenkomt conform de volgende richtlijnen:

73/23/CEE, 9368/CEE, 89/336/CEE, 9231/CEE

and has been designed in conformance with the following norms:

ed è stata progettata in conformità alle seguenti normative:

und in Übereinstimmung mit den nachstehenden Normen hergestellt wurde:

y ha sido diseñado de acuerdo con las siguientes normas:

et qu'il a été conçu en conformité avec les normes:

og er produsert iht. følgende standarder:

en is ontworpen conform de volgende normen:

EN 50192, EN 50199, EN 60529, EN 60974-1

Ing. Giovanni Pedrazzo

Amministratore Delegato

LINCOLN ELECTRIC ITALIA S.r.l., Via degli Artigiani 80, 17015 Celle Ligure (SV), Italia

ENGLISH INDEX

Safety...................................................................................................................................................4

Installation and Operator Instructions............................................................................................5

PRO-CUT 25 Technical Specifications................................................................................................8

Electromagnetic Compatibility (EMC)..............................................................................................9

INDICE

Sicurezza........................................................................................................................................... 10

Installazione e Istruzioni Operative .............................................................................................. 11

Pro-Cut 25 Specifiche tecniche...................................................................................................... 15

Compatibilità elettromagnetica (EMC) ......................................................................................... 15

INHALTSVERZEICHNIS DEUTSCH

Sicherheitsmaßnahmen / Unfallschutz......................................................................................... 17

Installation und Bedienungshinweise .......................................................................................... 18

PRO-CUT 25 Technische Daten........................................................................................................ 21

Elektromagnetische Verträglichkeit (EMC)................................................................................... 22

ÍNDICE EN ESPAÑOL

Seguridad ......................................................................................................................................... 23

Instalación e Instrucciones de Funcionamiento ......................................................................... 24

PRO-CUT 25 Características Técnicas.............................................................................................. 28

Compatibilidad Electromagnética (EMC)...................................................................................... 28

INDEX FRANCAIS

Sécurité ............................................................................................................................................ 30

Installation et Instructions d'Utilisation....................................................................................... 31

PRO-CUT 25 Caractéristiques Techniques ..................................................................................... 35

Compatibilité Electromagnétique (EMC)...................................................................................... 35

INNHOLD

Sikkerhetsregler .............................................................................................................................. 37

Installasjon og brukerinstruksjon.................................................................................................. 38

PRO-CUT 25 Tekniske Data............................................................................................................... 41

Elektromagnetisk Kompatibilitet (EMC)........................................................................................ 42

NEDERLANDSE INDEX

Veiligheid ......................................................................................................................................... 43

Installatie en Bediening.................................................................................................................. 44

Technische Specificatie .................................................................................................................. 48

Elektromagnetisch Compatibiliteit (EMC) .................................................................................... 48

Spare Parts, Parti di Ricambio, Ersatzteile, Lista de Piezas de Recambio, Pièces détachées,

Delliste, Onderdelen ....................................................................................................................... 50

Electrical Schematic, Schema Elettrico, Schaltplan, Esquema Eléctrico, Schéma électrique,

Elektrisk Skjema, Elektrisch Schema .............................................................................................53

Accessories, Accessori, Zubehör, Accesorios, Accessoires, Reservedeler, Accessoires.......... 54

Safety

WARNING

This equipment must be used by qualified personnel. Be sure that all installation, operation,

maintenance and repair procedures are preformed only by qualified individuals. Read and

understand this manual before operating this equipment. Failure to follow the instructions

in this manual could cause serious personal injury, loss of life, or damage to this equipment..

Read and understand the following explanations of the warning symbols. Lincoln Electric

Italia is not responsible for damages caused by improper installation, improper care or

abnormal operation.

WARNING: This symbol indicates that instructions must be followed to avoid

serious personal injury, loss of life, or damage to this equipment. Protect

yourself and others from possible serious injury or death.

Cutting sparks can cause explosion or

fire. Keep flammables away from

cutting. Do not cut near flammables.

Have a fire extinguisher nearby, and have

a watch person ready to use it. Do not

cut on drums or any closed container.

The plasma arc can cause injury and

burns. Keep your body away from nozzle

and plasma arc. Turn off power before

disassembling torch. Do not grip

material near cutting path. Wear

complete body protection.

Electric shock from torch or wiring can

kill. Wear dry insulating gloves. Do not

wear wet or damaged gloves. Protect

yourself from electric shock by insulating

yourself from work and ground.

Disconnect input plug or power before

working on machine.

Breathing cutting fumes can be

hazardous to your health. Keep your

head out of the fumes. Use forced

ventilation or local exhaust to remove

the fumes. Use ventilating fan to

remove fumes.

Arc rays can burn eyes and injure skin.

Wear hat and safety glasses. Use ear

protection and button shirt collar. Use

welding helmet with correct shade of

filter. Wear complete body protection.

Become trained and read the

instructions before working on the

machine or cutting.

Do not remove or paint over (cover) the label.

READ AND UNDERSTAND INSTRUCTIONS: Read and understand this manual

before operating this equipment. Plasma cutting or gouging can be

hazardous. Failure to follow the instructions in this manual could cause

serious personal injury, loss of life, or damage to this equipment.

ELECTRICALLY POWERED EQUIPMENT: Turn off input power using the

disconnect switch at the fuse box before working on this equipment. Ground

this equipment in accordance with local electrical regulations.

ELECTRIC AND MAGNETIC FIELDS MAY BE DANGEROUS: Electric current flowing

through any conductor creates electric and magnetic fields (EMF). EMF fields

may interfere with some pacemakers, and welders having a pacemaker should

consult their physician before operating this equipment.

CYLINDER MAY EXPLODE IF DAMAGED: Use only compressed gas cylinders

containing the correct shielding gas for the process used and properly

operating regulators designed for the gas and pressure used. Always keep

cylinders in an upright position securely chained to a fixed support. Do not

move or transport gas cylinders with the protection cap removed. Do not

allow the torch, work clamp or any other electrically live part to touch a gas

cylinder. Gas cylinders must be located away from areas where they may be

subjected to physical damage or the cutting process including sparks and

heat sources.

WORK MATERIALS CAN BURN: Cutting generates a large amount of heat. Hot

surfaces and materials in work area can cause serious burns. Use gloves and

pliers when touching or moving materials in the work area.

CE COMPLIANCE: This equipment complies to the Central European directives.

SAFETY MARK: This equipment is suitable for supplying power for cutting

operations carried out in an environment with increased hazard of electric

shock.

Installation and Operator Instructions

Read this entire section before installation

or operation of the machine.

Location and Environment

This machine will operate in harsh

environments. However, it is important

that simple preventative measures are

followed to assure long life and reliable

operation.

•Do not place or operate this machine on

a surface with an incline greater than

15° from horizontal.

•This machine must be located where

there is free circulation of clean air

without restrictions for air movement

to and from the air vents. Do not cover

the machine with paper, cloth or rags

when switched on.

•Dirt and dust that can be drawn into the

machine should be kept to a minimum.

•This machine has a protection rating of

IP21. Keep it dry when possible and do

not place it on wet ground or in

puddles.

•Locate the machine away from radio

controlled machinery. Normal

operation may adversely affect the

operation of nearby radio controlled

machinery, which may result in injury or

equipment damage. Read the section

on electromagnetic compatibility in this

manual.

•Do not operate in areas with an ambient

temperature greater than 40°C.

Input Supply Connection

Check the input voltage, phase, and

frequency supplied to this machine before

turning it on. The allowable input voltage

is indicated in the technical specification

section of this manual and on the rating

plate of the machine. Verify the

connection of grounding wires from the

machine to the input source.

Make sure the amount of power available

from the input connection is adequate for

normal operation of the machine. The

necessary fuse and cable sizes are indicated

in the technical specification section of this

manual.

This machine is designed to operate on

engine driven generators as long as the

230Vac auxiliary can supply adequate

power as indicated in the technical

specification section of this manual. The

auxiliary supply of the generator must also

meet the following conditions.

•The AC waveform peak voltage is below

400V.

•The AC waveform frequency is between

50 and 60 hertz.

•The RMS voltage of the AC waveform is

always greater than 208Vac.

It is important to check these conditions

because many engine driven generators

produce high voltage spikes. Operation of

this machine on engine driven generators

not conforming to these conditions is not

recommended and may damage the

machine.

Compressed Air or Gas Connection

A source of clean, dry air or nitrogen must

be supplied to the machine. Oil in the air is

a severe problem and must be avoided, use

an oil filter if necessary. The supply

pressure must be between 5.0 to 10.3 Bar

and the flow rate is approximately 113

L/min. Failure to observe these

precautions could result in excessive

operating temperatures or damage to the

torch.

Output Connections

This machine is sent from the factory with

a PCT-20 cutting torch and work clamp

installed. The work clamp must be securely

connected to the work piece. If the work

piece is painted or extremely dirty it may

be necessary to expose the bare metal in

order to make a good electrical

connection. Do not remove the work

clamp during cutting, plasma cutting

generates high voltages that can kill.

Front Control Panel

The POWER SWITCH controls the input

power to the machine. After input power

is connected and this switch is turned on,

the back lit POWER symbol on the control

panel will light up to indicate the machine

is ready.

The PURGE button is used to turn on the

flow of compressed air through the torch.

While pressing this button the air pressure

supplied to the torch can be regulated

using the built-in regulator and pressure

gage. Set the air pressure to 4.4 Bar while

air is flowing through the torch. Air flow is

required for proper adjustment.

The OUTPUT CURRENT KNOB is used to set

the output current used during cutting,

from 12A to 25A. The pilot arc current

does not change, it is always 12A.

The back lit GAS PRESSURE symbol on the

control panel will light up to indicate when

the inlet air pressure is too low. The inlet

air pressure must be between 5.0 and 10.3

Bar. The machine will not operate when

this GAS PRESSURE symbol is lit.

The back lit THERMAL symbol on the

control panel will light up when the

machine is overheated and the output has

been turned off. This will occur if the

ambient temperature is above 40°C and

the duty cycle of the machine has been

exceeded. Leave the machine on to allow

the internal components to cool, when

THERMAL symbol turns off normal

operation is possible

The back lit SAFETY symbol on the control

panel will light up when the machine

detects a parts-in-place error. A parts-in-

place error means that a problem with the

torch consumables has been detected and

the output of the machine has been

disabled. To correct this error, turn the

machine off and inspect the torch

consumables. The consumables must be in

good condition and installed correctly for

the machine to operate. For safety

reasons, the machine must be turned off

and then back on to reset this error.

Operation

When preparing to cut, make sure you

have all materials needed to complete the

job and have taken all safety precautions.

Install the machine as instructed in this

manual and remember to attach the work

clamp to the work piece. Check the

regulation of air pressure by pressing the

PURGE button and adjusting the gas

regulator. Do not set the air pressure

when air is not flowing through the torch.

When ready to cut make certain all safety

precautions have been taken, be prepared

for the pilot arc to ignite, and pull the

trigger.

•The air will flow for a preflow time of 2

seconds and the pilot arc will start.

(Exceptions: The first time that the

trigger is pulled after the machine is

turned on, or after a thermal overload,

it will be ignored. This is a safety feature

to prevent the pilot arc from firing

unexpectedly or if the torch button is

pressed because it is laying up against

something. The other exception is if the

machine is in postflow, then the preflow

time is skipped and the pilot arc will

start immediately.)

•The pilot arc will run for 3 seconds and

shut off automatically unless the arc is

brought in contact with the work piece

and the arc is transferred. Avoid

excessive pilot arc time by transferring

the arc to the work piece quickly.

•When the arc is brought within 3 to 6

mm from the work piece the arc will

transfer, the output current will

increase to the setting on the control

panel, and the cut can last indefinitely

(or until the duty cycle of the machine is

exceeded).

If you must pierce the work

piece, lower the torch onto

the metal at a 30° angle away

from the operator. This will

blow the dross (melted metal)

away from the torch tip.

Slowly rotate the torch to the vertical

position as the arc becomes deeper. Once

the work piece is pierced normal cutting

can occur.

Keep moving while

cutting and cut at a

steady speed so that the

arc leg is 10° to 20°

behind the travel

direction. Use a 5° to 15°

leading angle in the

direction of the cut.

Then the cut is finished

release the trigger and the arc will stop.

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.

For accurate cutting, the right side of the

cut is more square than the left as viewed

along the direction of travel. Clean spatter

and scale from the nozzle frequently.

Shown here is the cutting capacity of the

Pro-Cut 25 when cutting on mild steel. Use

this graph to determine recommended

travel speeds for mild steel.

The nozzle my be dragged on the metal

surface, touching it lightly to the surface.

If the back lit SAFETY symbol on the control

panel lights up at any time; check the

following:

•Check the assembly of the torch

consumables. If they are not properly in

place, the machine will not start. Make

sure the shield cup is hand tight. Do not

use pliers or over tighten.

Pro-Cut 25 Cut Capacity

100

125

150

175

200

2345678910

Metal Thickness (mm)

Recommended Travel Speed

(cm/min)

•Check the condition on 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. Avoid excessive pilot

arc time; the pilot arc is designed to

transfer the arc to the work piece and

not for numerous starts without

cutting.

•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 1.5mm. A green and

erratic arc will indicate definite

electrode failure and the electrode

should be replaced immediately.

•Replace the nozzle when the orifice exit

is eroded away or oval shaped.

•After the problem is found, or if there is

nothing apparently wrong, reset the

machine by turning the power switch

OFF and then ON again.

Consumable Life

The expected life for the Pro-Cut 25’s

electrode under normal operating

conditions is approximately 1000

starts/cuts. An erosion of 1.5mm 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.

PRO-CUT 25 Technical Specifications

INPUT

Input Voltage

230V ±15%

Single Phase

Input Power at Rated Output

3.1kW @ 100% Duty Cycle

4.0kW @ 60% Duty Cycle

Frequency

50/60 Hertz (Hz)

RATED OUTPUT

Duty Cycle

(Based on a 10 min. period)

100%

60%

Output Current

20A

25A

Output Voltage

88.0 Vdc

90.0 Vdc

OUTPUT RANGE

Cutting Current Range

12-25 Amps

Maximum Open Circuit Voltage

400 Vdc

Pilot Current

12 Amps

COMPRESSED AIR or GAS

Required Flow Rate

4.4 Bar @ 113 L/min

Required Inlet Pressure

5.0 Bar to 10.3 Bar

RECOMMENDED INPUT CABLE AND FUSE SIZES

Fuse or Circuit Breaker Size

16A Superlag

Type of Plug

SCHUKO 16A/250V

(Included with Machine)

Input Power Cable

3 Conductor, 1.5mm2

Physical Dimensions

Height

260 mm

Width

160 mm

Length

410 mm

Weight

15.9 Kg

Operating Temperature

–20°C to +40°C

Storage Temperature

-25°C to +55°C

For any maintenance or repair operations it is recommended to contact the nearest

technical service center or Lincoln Electric Italia. Maintenance or repairs preformed by

unauthorized service centers or personnel will null and void the manufacturers warranty.

Electromagnetic Compatibility (EMC)

This machine has been designed in accordance with all relative directives and norms.

However, it may still generate electromagnetic disturbances that can affect other systems

like telecommunications (telephone, radio, and television) or other safety systems. These

disturbances can cause safety problems in the affected systems. Read and understand this

section to eliminate or reduce the amount of electromagnetic disturbance generated by

this machine.

WARNING: This machine has been designed to operate in an industrial area. To

operate in a domestic area it is necessary to observe particular precautions to

eliminate possible electromagnetic disturbances. The operator must install and

operate this equipment as described in this manual. If any electromagnetic

disturbances are detected the operator must put in place corrective actions to eliminate

these disturbances with, if necessary, assistance from Lincoln Electric Italia. Do not modify

this machine without the written approval of Lincoln Electric Italia.

Before installing the machine, the operator must check the work area for any devices that

may malfunction because of electromagnetic disturbances. Consider the following.

•Input and output cables, control cables, and telephone cables that are in or adjacent to

the work area and the machine.

•Radio and/or television transmitters and receivers.

•Computers or computer controlled equipment.

•Safety and control equipment for industrial processes.

•Personal medical devices like pacemakers and hearing aids.

•Equipment for calibration and measurement.

•Check the electromagnetic immunity for equipment operating in or near the work area.

The operator must be sure that all equipment in the area is compatible. This may require

additional protection measures.

•The dimensions of the work area to consider will depend on the construction of the area

and other activities that are taking place.

Consider the following guidelines to reduce electromagnetic emissions from the machine.

•Connect the machine to the input supply according to this manual. If disturbances occur

if may be necessary to take additional precautions such as filtering the input supply.

•The output cables should be kept as short as possible and should be positioned together.

•If possible connect the work piece to ground in order to reduce the electromagnetic

emissions. The operator must check that connecting the work piece to ground does not

cause problems or unsafe operating conditions for personnel and equipment.

•Shielding of cables in the work area can reduce electromagnetic emissions. This may be

necessary for special applications.

Sicurezza

AVVERTENZA

Questa macchina deve essere impiegata solo da personale qualificato. Assicuratevi che tutte

le procedure di installazione, impiego, manutenzione e riparazione vengano eseguite

solamente da persone qualificate. Leggere e comprendere questo manuale prima di

mettere in funzione la macchina. La mancata osservanza delle istruzioni di questo manuale

può provocare seri infortuni, anche mortali, alle persone, o danni alla macchina. Leggere e

comprendere le spiegazioni seguenti sui simboli di avvertenza. La Lincoln Electric Italia non

assume alcuna responsabilità per danni conseguenti a installazione non corretta, carenze di

cautela o impiego in modo anormale.

AVVERTENZA: Questo simbolo indica che occorre seguire le istruzioni per

evitare seri infortuni, anche mortali, alle persone, o danni a questa macchina.

Proteggete voi stessi e gli altri dalla possibilità di seri infortuni anche mortali.

Le scintille prodotte dal taglio possono

provocare esplosioni o incendi. Tenete a

distanza dal taglio i materiali

infiammabili. Non tagliate vicino a

materiali infiammabili. Tenete un

estintore a portata di mano, con una

persona di guardia pronta ad usarlo. Non

fate tagli su bidoni o altri contenitori

chiusi.

L’arco plasma può provocare bruciature e

ferite. Tenete il corpo a distanza dalla

punta di contatto e dall’arco plasma.

Togliete la tensione prima di smontare la

torcia. Non afferrate pezzi di materiale

vicino alla zona di taglio. Indossate una

protezione completa per il corpo.

Una scossa elettrica dalla torcia o dai cavi

può uccidervi. Indossate guanti isolanti

asciutti. Non usate guanti bagnati o

danneggiati. Proteggetevi dalle scosse

elettriche tenendovi isolati dal pezzo in

lavorazione e dalla terra. Prima di

lavorare sulla macchina staccate la spina

di alimentazione o togliete

l’alimentazione in altro modo.

Respirare i fumi del taglio può essere

pericoloso per la salute. Tenete la testa

fuori dai fumi. Usate ventilazione forzata

o aspirazione localizzata per asportare i

fumi. Usate un ventilatore per

allontanare i fumi.

I raggi dell’arco possono bruciare gli

occhi e ferire la pelle. Indossate la

maschera o gli occhiali di sicurezza.

Usate le cuffie antirumore e abbottonate

il colletto della camicia. Usate una

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