Lincoln Electric TOMAHAWK 1025 Bedienungsanleitung

IM2014

04/2016

REV06

TOMAHAWK1025 & 1538

OPERATOR’S MANUAL

ENGLISH

Lincoln Electric Bester Sp. z o.o.

ul. Jana III Sobieskiego 19A, 58-263 Bielawa, Poland

www.lincolnelectric.eu

English English

Declaration of conformity

Lincoln Electric Bester Sp. z o.o.

Declares that the plasma machine:

TOMAHAWK1025

TOMAHAWK1538

conforms to the following directives:

2014/35/EU , 2014/30/EU

and has been designed in compliance with the

following standards:

EN 60974-1:2012; EN 60974-10:2014

20.04.2016

Piotr Spytek

Operations Director

Lincoln Electric Bester Sp. z o.o., ul. Jana III Sobieskiego 19A, 58-263 Bielawa, Poland

07/11

English English

12/05

THANKS! For having choosen the QUALITY of the Lincoln Electric products.

Please Examine Package and Equipment for Damage. Claims for material damaged in shipment must be notified

immediately to the dealer.

For future reference record in the table below your equipment identification information. Model Name, Code &

Serial Number can be found on the machine rating plate.

Model Name:

………………...…………………………….…………………………………………………………………………………………..

Code & Serial number:

………………….……………………………………………….. …………………………………………………….……………..

Date & Where Purchased:

…………………………………………………………………... ……………………….…………………………………………..

ENGLISH INDEX

Safety .............................................................................................................................................................................. 1

Installation and Operator Instructions .............................................................................................................................. 2

Electromagnetic Compatibility (EMC) .............................................................................................................................. 7

Technical Specifications .................................................................................................................................................. 8

WEEE.............................................................................................................................................................................. 8

Spare Parts...................................................................................................................................................................... 8

Electrical Schematic ........................................................................................................................................................ 8

English English

Safety

01/11

WARNING

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

procedures are performed only by qualified person. 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 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.

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 shall consult their physician before operating this

equipment.

CE COMPLIANCE: This equipment complies with the European Community Directives.

ARTIFICIAL OPTICAL RADIATION: According with the requirements in 2006/25/EC Directive and

EN 12198 Standard, the equipment is a category 2. It makes mandatory the adoption of Personal

Protective Equipments (PPE) having filter with a protection degree up to a maximum of 15, as

required by EN169 Standard.

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.

SAFETY MARK: This equipment is suitable for supplying power for cutting operations carried out in

an environment with increased hazard of electric shock.

EQUIPMENT WEIGHT OVER 30kg: Move this equipment with care and with the help of another

person. Lifting may be dangerous for your physical health.

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.

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.

English English

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.

Installation and Operator Instructions

Read this entire section before installation or operation

of the machine.

Location and Environment

This machine can 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.

Do not use this machine for pipe thawing.

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 IP23. 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.

Duty Cycle

The duty cycle of a plasma machine is the percentage of

time in a 10 minute cycle at which the operator can

operate the machine at rated cutting current.

Example: 60% duty cycle means that is possible cut for

6 minutes, then the machine stops for 4 minutes.

Refer to the Technical Specification section for more

information about the machine rated duty cycles.

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.

Be sure that the machine is grounded.

Make sure the amount of power available from the input

connection is adequate for normal operation of the

machine. The fuse rating and cable sizes are both

indicated in the technical specification section of this

manual.

This machine is designed to operate on engine driven

generators as long as the 400Vac 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 700V.

The AC waveform frequency is between 50 and 60

Hz.

The RMS voltage of the AC waveform is always

equal to 400Vac ±15%.

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.

English English

Output Connections

WARNING

Use ONLY the torch supplied with this machine. For a

replacement refer to the Maintenance section of this

manual.

WARNING

TORCH PROTECTION: The torch delivered with the

power source is equipped with a safety device that

prevents the operator from accidental contact with

electrically live parts.

WARNING

Always turn OFF the machine when working on the

torch.

WARNING

Do not remove the work clamp during cutting, plasma

cutting generates high voltages that can kill.

WARNING

Open Circuit Voltage U0> 100VDC. For more

information refer to the Technical Specification section.

Torch Connector:

Connect here the cutting

torch. The torch

connection to the power

source is very easily

performed through a quick-

connector carrying the

torch trigger circuit, the gas

line and the torch power

cable.

Positive Quick Disconnect:

Positive output connector

for the cutting circuit. As

far the ground connection,

this is to be connected to

the work piece and to a

"DINSE" connector on the

front of the power source.

Torch Connector Polarization Key:

This Plasma Cutting Machine shall be used with its

specific torch. The polarized torch connector avoid the

risk to use the machine with a not proper torch model.

The position of the polarized key is shown in the table

below.

Polarization Key

60A machines

100A machines

Controls and Operational Features

Machine Auto-Test:

When the machine is turned ON, an auto-test is

executed; during this test all of the LEDs of the

Commands Front Panel lights up. If one or some LED

remains OFF, contact the nearest technical service

center or Lincoln Electric and report the LED Status

found on the machine Front Panel.

Front Panel Controls

Output Current Knob:

Potentiometer used to set the output

current used during cutting. Refer to the

Technical Specification section for more

information about the machine rated

current range.

Gas Purge:

The Output Current Knob completely

rotated counterclockwise enables the gas

purge function.

Power ON/OFF LED:

It lights up when the machine is ON.

Blinking LED: Mains out of range

condition. The machine is disabled:

when the mains returns in the correct

range, the machine restart automatically.

Note: The Fan could be automatically

switched OFF if the error condition

persist for more than 2seconds.

Output LED:

The cutting torch is energized.

Blinking LED: Internal auxiliary

undervoltage condition. The machine

needs to be turned OFF then ON again to

restart.

Thermal LED:

The machine is overheated and the

output has been disabled. This usually

occurs when the duty cycle of the

machine has been exceeded. Leave the

machine ON to allow the internal

components to cool. When the thermal

LED turns off, normal operation is again

possible.

Low gas pressure condition LED:

With this LED ON the machine stops

cutting or gouging operations. The

machine restart automatically when a

correct gas pressure is detected.

To check / adjust the primary gas

pressure (see recommended values in

the Tecnical Specifications of this

manual):

When this LED lights up, for 10

seconds the machines goes

automatically in Purge mode.

During Purge time check and adjust

the gas pressure through the

manometer and primary gas

pressure regulator knob.

If necessary, check and adjust also

the inlet gas pressure through the

commands of the inlet primary gas.

English English

PIP LED:

Part in place condition: the torch retaining

cap (or the torch connector) is not

properly screwed on the torch head (or in

the machine torch connector).

To restore the machine:

Screw firmly the torch retaining cap

(or the torch connector).

After the torch is restored, the

machine cannot restart for about 5

seconds. During this time the PIP

LED blinks.

(Note: When the LED is blinking, if

another PIP error occours or if the

Torch Trigger pushbutton is pressed

the machine returns to the error

condition: PIP LED returns steady

ON and the restoring procedure

begins again).

When the PIP LED turns OFF the

machine is ready to operate.

TH1025

TH1538

Primary Gas Pressure Gauge and

Regulator Knob:

Allow to regulate and monitoring the

primary gas pressure.

The inlet primary gas pressure is

limited by this pressure regulator, set

at factory at 5.5bar. In case to adjust

the gas pressure, put the machine in

Purge mode.

Cutting Operating Mode Selection:

Press the pushbutton to select the

desired operating mode (the “ON” LED

indicates the selected mode):

CUT (top LED ON): for cutting or

piercing operations on a solid work

piece.

GRID (middle LED ON): for cutting

operations on a grid work piece.

GOUGE (bottom LED ON): for

removing material from a solid work

piece (e.g.: removing a failed welded

bead).

It is possible change the Operating Mode

with the machine at idle and also during

the Purge, Post Flow and Cooling time.

Pressing the pushbutton during Pilot Arc

or Cutting time has no effects.

Error condition list.

If occurs, try to turn Off the machine, wait for a few

seconds, then turn ON again. If the error remains, a

maintenance is required. Please contact the nearest

technical service center or Lincoln Electric and report the

LED Status found on the machine Front Panel.

Head Torch

On Blink Blink

This occurs if after 4seconds the Pilot Arc

isn’t transfered to the workpiece. The

machine stops the pilot arc to avoid

overheating on the Torch Head.

To restore the machine:

Release the Torch Trigger

pushbutton. The blinking LEDs are

now permanently ON

Press again the release the Torch

Trigger pushbutton.

No pilot arc

estabilished

On On On

The Torch Trigger pushbutton is pressed.

During this period the machine try to start

the pilot arc for 4 times. If the pilot arc

doesn’t start the machine automatically

goes in a safe condition that allow to

check as necessary.

To restore the machine:

Turn OFF the Power switch.

Check the correct placement of the

Torch Head consumables and parts.

Check the Torch electrical

connections.

Turn ON again the machine.

Trigger

Pushed

On On On On

This occurs if the machine is switched

ON (or if it restart after cooling time) with

the Torch Trigger pushbutton hold. This

status avoids unsafe operating

conditions: manual cutting or gouging

processes must be started ONLY under

the direct control of the operator.

To restore the machine:

Release the Torch Trigger

pushbutton.

Press again the Torch Trigger

pushbutton.

If this error condition persist check for

eventual malfunctions of the the Torch

Trigger pushbutton.

Rear Panel Controls and Connections

A. Fan: This machine has a

F.A.N. (Fan As Needed)

circuitry inside: the fan is

automatically turned ON or

OFF. This feature reduces

the amount of dirt which can

be drawn inside the machine

and reduces power

consumption. When the

machine is turned ON the fan

will turn ON. The fan will

continue to run whenever the

torch trigger pushbutton is

English English

pressed. If the torch trigger pushbutton is released

for more than five minutes, the fan will turn OFF.

B. Power Switch: It turns ON / OFF the input power to

the machine.

C. Input cable: Connect it to the mains.

D. Gas Inlet: Connect here the hose carrying the gas

to the machine.

WARNING

A clean, dry primary gas (air or nitrogen) must be

supplied to the machine. A pressure setting above

7,5bar could damage the torch. Failure to observe

these precautions could result in excessive

operating temperatures or damage to the torch.

Cutting Process

The air plasma cutting process uses air or nitrogen as

primary cutting gas and as torch cooling gas.

The pilot arc is struck as follow: the torch button

energize an electrovalve (solenoid valve). This valve

lets the gas flow during the cutting and the post-flow

stages.

The design concept at the basis of these power sources

is to have available a current which remains constant at

the set value, independently from the length of the

plasma arc.

When preparing to operate, 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.

With the machine switched OFF, prepare the torch

with the consumables adequate to the desired

process (CUT / GRID / GOUGE). Refer to the

Torches Instruction Manual to select the correct

combination of consumables.

Connect the Torch and the worck cable to the

machine.

Turn ON the Power Switch placed on the back of

the machine; the Power ON/OFF LED on the front

panel will turn ON. The unit is now ready to

operate.

Check that the primary gas is available through the

Gas Purge function.

Select the desired Operating Mode process.

Set the desired current value with the Output

Current knob.

To start the selected process just press the torch button,

making sure you are not aiming the torch gas blow

towards people or foreign objects. During the process it

is possible to hold the torch away from the work piece for

an extended period of time.

Once the process is terminated releasing off the torch

button will cause the plasma arc to be turned off; the gas

flow will continue to allow the cooling down of the torch.

The Post Flow time is proportional to the selected cutting

current and it is divided into 4 time ranges:

Selected Cutting Current Post Flow Time

Less than 30A 15seconds

Between 30A and 40A 20seconds

Between 40A and 50A 25seconds

Greater than 50A 30seconds

Maintenance

WARNING

For any maintenance or repair operations it is

recommended to contact the nearest technical service

center or Lincoln Electric. Maintenance or repairs

performed by unauthorized service centers or personnel

will null and void the manufacturers warranty.

The frequency of the maintenance operations may vary

in accordance with the working environment. Any

noticeable damage should be reported immediately.

Check cables and connections integrity. Replace, if

necessary.

Regularly clean the torch head, check its

consumables and if necessary replace them.

WARNING

Refer to the torch instructions before changing or

servicing the torch.

Keep clean the machine. Use a soft dry cloth to

clean the enclosing case, especially the airflow inlet

/ outlet louvers.

WARNING

Do not open this machine and do not introduce anything

into its openings. Power supply must be disconnected

from the machine before maintenance and service. After

each repair, perform proper tests to check safety

requirements.

English English

Cutting Speed

The cutting speed is a function of:

Thickness and of material to be cut.

Value of set current. The current setting affects the quality of the cut edge.

Geometrical shape of the cut (whether straight or curved).

In order to provide indications on the most suitable setting, the following table was established, based on tests performed

on an automatic test-bench; the best results however can only be achieved from direct experience by the operator in his

actual working conditions.

TH1025 TH1538

Current

(A)

Speed (cm/min.) Current

(A)

Speed (cm/min.)

Thickness MILD

STEEL ALUMINUM STAINLESS

STEEL

MILD

STEEL ALUMINUM STAINLESS

STEEL

4 mm --- --- --- --- --- --- --- ---

6 mm --- --- --- --- --- --- --- ---

¼ ” --- --- --- --- --- --- --- ---

8 mm --- --- --- --- --- --- --- ---

10 mm 60 119 206 105 --- --- --- ---

½ ” 60 91 157 77 --- --- --- ---

15 mm 60 72 122 55 100A 180 223 147

¾ ” 60 48 75 40 100A 117 152 99

20 mm 60 43 65 36 100A 106 140 91

25 mm 60 26 36 17 100A 70 98 63

1 ” 60 25 35 16 100A 68 95 61

30 mm 60 --- 22 --- 100A 50 73 46

1 ¼ ” 60 --- 16 --- 100A 45 66 42

35 mm --- --- --- --- 100A 38 55 36

1 ½ ” --- --- --- --- 100A 32 48 31

English English

Electromagnetic Compatibility (EMC)

01/11

This machine has been designed in accordance with all relevant directives and standards. 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.

This machine has been designed to operate in an industrial area. 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. This equipment does not comply with IEC 61000-3-12. If it is connected to a public low-

voltage system, it is responsibility of the installer or user of the equipment to ensure, by consultation with the distribution

network operator if necessary, that the equipment may be connected.

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. Equipment for calibration and measurement.

Personal medical devices like pacemakers and hearing aids.

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.

WARNING

The Class A equipment is not intended for use in residential locations where the electrical power is provided by the public

low-voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations,

due to conducted as well as radio-frequency disturbances.

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