Lincoln Electric PRO-CUT 40 Operator'S Manual Download Page 3

– 3 –

FOR ELECTRICALLY
powered equipment.

6.a. Turn off input power using the disconnect

switch at the fuse box before working on
the equipment.

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.

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 main-
tained in good condition.

5.b. Always keep cylinders in an upright position securely

chained to an undercarriage or fixed support.

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.

5.d. Never allow any part of the electrode, torch or any other

electrically “hot” parts to touch a cylinder.

5.e. Keep your head and face away from the cylinder valve outlet

when opening the cylinder valve.

5.f. Valve protection caps should always be in place and hand

tight except when the cylinder is in use or connected for
use.

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.

Apr. ‘93

ELECTRIC AND MAGNETIC FIELDS
may be dangerous

8.a. Electric current flowing through any con-

ductor causes localized Electric and
Magnetic Fields (EMF). Cutting or gouging
current creates EMF fields around torch
cables and cutting machines. 

8.b. EMF fields may interfere with some pacemakers, so opera-

tors having a pacemaker should consult their physician
before cutting or gouging.

8.c. Exposure to EMF fields during cutting or gouging may have

other health effects which are now not known.

8d. All operators should use the following procedures in order to

minimize exposure to EMF fields from the cutting or gouging
circuit:

8.d.1. Route the torch and work cables together - Secure

them with tape when possible.

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.

8.d.4. Connect the work cable to the workpiece as close as

possible to the area being cut or gouged.

8.d.5. Do not work next to cutting power source.

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.

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.

PLASMA ARC can injure.

7.a. Keep your body away from nozzle and

plasma arc.

7.b. Operate the pilot arc with caution. The pilot arc is capable of

burning the operator, others or even piercing safety clothing.

Summary of Contents for PRO-CUT 40

Page 1: ...and Cutting Products Premier Manufacturer of Industrial Motors IM422 A October 1995 Safety Depends on You Lincoln plasma cutting equipment is designed and built with safety in mind However your overa...

Page 2: ...spatter or metal ELECTRIC SHOCK can kill 1 a The electrode and work or ground circuits are electrically hot when the power source is on Do not touch these hot parts with your bare skin or wet clothin...

Page 3: ...ocalized Electric and Magnetic Fields EMF Cutting or gouging current creates EMF fields around torch cables and cutting machines 8 b EMF fields may interfere with some pacemakers so opera tors having...

Page 4: ...et non inflammables 4 Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talon...

Page 5: ...nts 10 Pilot Arc Discussion 11 Procedure Recommendations 11 General 11 Thin Gauge Sheet Metal 11 Expanded Metal 11 Thick Sections of Metal 12 In All Cases 12 Suggestions for Extra Utility from the PRO...

Page 6: ...e the information must be followed to avoid minor personal injury or damage to this equipment CAUTION Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title pa...

Page 7: ...minimum preheat temperature is recommended as a starting point Higher tempera tures may be used as required by the job conditions and or prevailing codes If cracking or excessive hardness occurs on th...

Page 8: ...pproximately 4 7 cfm 133 l min Failure to observe these precautions could result in excessive operating temperatures or damage to the torch HIGH FREQUENCY INTERFERENCE PROTECTION The PRO CUT 40 employ...

Page 9: ...baffle c Hold resistor body with electrically insulated glove DO NOT TOUCH TERMINALS Carefully lift mylar insulation Connect resistor terminals across two hex head cap screws in position shown Hold in...

Page 10: ...Safety LED is glowing push the Safety Reset button If there is no problem the LED will go off If there is a problem refer to Step 5 of the Test Step Chart and the Troubleshooting Guide D Set the Purg...

Page 11: ...e operating manual and on the machine The S19425 1 Drag Cup is recommended when the output control is set in the blue range to pro tect the torch from dross and improper arcing conditions Use proper c...

Page 12: ...System If it becomes absolutely necessary to cut through a very thick section the air flow at the regulator on the back of the machine may be raised to 75 psi 516 kPa to get a better cut result and m...

Page 13: ...cable jacket Replace if necessary 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 rel...

Page 14: ...at rated input voltage Make ohmme ter checks only after power has been disconnected from machine and after capacitors have been dis charged Certain high voltage connections have been insulated with RT...

Page 15: ...E LED must be lit when refer to the section under that combination air is flowing 2 Check for proper TRIGGER SWITCH operation There should be continuity between J20 2 and J20 4 when the trigger switch...

Page 16: ...not correct replace the transformer T1 4 Check for 115VAC between J19 9 lead number 215B and J19 7 lead number 215D at the high frequency module 115VAC should be applied for approximately 1 2 second...

Page 17: ...y or greasy and in good shape LED begins blinking There was a brief arc Replace the consumables if necessary 2 Replace the PWM CONTROL BOARD 3 Replace the MICRO CONTROL BOARD The arc starts but sputte...

Page 18: ...BOARD Alternating AIR MALFUNCTION LED lights 1 Replace MICRO CONTROL BOARD The SAFETY LED is lit 1 The machine will not operate The machine senses that the nozzle is not in place or the operators coul...

Page 19: ...s on Switch PC Board 9 pos to 4 5 neg 9 neg to 4 5 pos Remove output load work to elec trode Test Result 1K ohms 100 ohms 100 ohms 1K ohms 1K ohms 100 ohms 100 ohms 1K ohms 100 ohms 500 ohms Conclusio...

Page 20: ...25 ohms high resistance 25 ohms high resistance 25 ohms high resistance 25 ohms high resistance 100 ohms 1K ohms 1K ohms 100 ohms 100 ohms 1K ohms 1K ohms 100 ohms 100 ohms 1K ohms 1K ohms 1K ohms 1K...

Page 21: ...1K ohms 100 ohms 1K ohms 100 ohms 1K ohms 100 ohms 1K ohms 100 ohms Conclusion OK Shorted OK Shorted OK Shorted OK Shorted OK Shorted Next Test Step 1 2 1 2 1 2 1 2 1 2 Repair Action Replace D9 In spa...

Page 22: ...ohms 1 K ohms 100 ohms 1K ohms 100 ohms 1K ohms 100 ohms 1K ohms Conclusion OK Shorted OK Open OK Open OK Open OK Open OK Open OK Open Next Test Step 1 2 1 2 1 2 1 2 1 2 1 2 1 2 Repair Action Replace...

Page 23: ...ed on 12 Connect an ohmmeter set for X1000 to the hex head screw terminals on the Switch PC board The meter will show the capacitors charging up The meter may take a minute or so to stabilize The valu...

Page 24: ...hine is on Normal OUTPUT ON On when there is voltage potential at the torch cutting or pilot Normal OUTPUT ON is blinking alternately with AIR PRESSURE when There is a problem with the microprocessor...

Page 25: ...ads shorted together 4 Foreign matter or interference behind the PC boards If PC board is visibly damaged mechanically such as a part vibrated off or was crushed inspect for cause then remedy before i...

Page 26: ...04 HIGH FREQ MODULE 607 R15 20K 5W C5 5 660VAC S2 S5 224B 224A LOCKED FAN THERMOSTAT 271 255B S3 S4 150 5W R14 255C THERMOSTAT B W W W 1 2 1 3 4 5 6 7 8 9 2 10 J4 1 3 4 5 6 7 8 2 J2 1 3 4 5 6 7 8 2 10...

Page 27: ...letin ED 80 or call 216 383 2259 and ask for the Welding School Registrar Lincoln Welding School BASIC COURSE 700 00 5 weeks of fundamentals There is a 10 discount on all orders of 50 00 or more for s...

Page 28: ...electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y...

Page 29: ...e Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fuma a Use ventila o e exhaust o para remover fumo da zona respirat ria Turn power off before servicing Desconectar el cable de ali mentaci...

Page 30: ...e such as gun and cable assem blies water coolers FAS TRAK or MIG TRAK equipment Power Arc generator welders Wire Feed Module Factory Installed and field installed optional equipment TO OBTAIN WARRANT...

Reviews: