Lincoln TOMAHAWK 625 Operator'S Manual Download Page 31 | Manualshive

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TOMAHAWK™ 625

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Summary of Contents for TOMAHAWK 625

Page 1: ...O NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READ ING THIS MANUAL AND THE SAFETY PRECAUTIONS CON TAINED THROUGHOUT And most importantly think before you act and be careful For use with machines having Code Number 11580 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 World ...

Page 2: ...n in posi tions such as sitting or lying make certain the insulation is large enough to cover your full area of physical contact with work and ground 1 d Always be sure the work cable makes a good electrical con nection with the metal being cut or gouged The connection should be as close as possible to the area being cut or gouged 1 e Ground the work or metal to be cut or gouged to a good elec tri...

Page 3: ...d 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 5 b Always keep cylinders in an upright position securely chained to an undercarriage or fixed support 5 c Cylinders should be located Away fro...

Page 4: ...NOTES ...

Page 5: ...riés et non inflammables 4 Des gouttes de laitier en fusion sont émises de lʼarc de soudage Se protéger avec des vêtements de protection libres de lʼhuile tels que les gants en cuir chemise épaisse pan talons sans revers et chaussures montantes 5 Toujours porter des lunettes de sécurité dans la zone de soudage Utiliser des lunettes avec écrans lateraux dans les zones où lʼon pique le laitier 6 Elo...

Page 6: ...y important when identifying the correct replacement parts On Line Product Registration Register your machine with Lincoln Electric either via fax or over the Internet For faxing Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it For On Line Registration Go to our WEB SITE at www li...

Page 7: ...ns B 7 General B 7 Suggestions for Extra Utility from the TOMAHAWK 625 System B 8 Torch Part Configuration B 9 B 10 ________________________________________________________________________________ Accessories Section C ________________________________________________________________________ Maintenance Section D Safety Precautions D 1 Routine Maintenance D 1 Periodic Maintenance D 1 ______________...

Page 8: ... 2 Input Supply Wires 1 Ground Wire 12 3 3 mm2 Type S SO ST STO or extra hard usage input cord AWG IEC Sizes Depth 18 9 in 480 mm Width 8 5 in 215 mm Height 15 2 in 385 mm Open Circuit Voltage 460 VDC For all plasma cutting applications Based on U S National Electrical Code Ambient Temperature 30o C or Less Pilot Current 12 Amps CURRENT AMPS 24 A 29 A 40 A VOLTAGE VOLTS 89 6VDC 91 8VDC 96 0VDC 208...

Page 9: ...nd solid state type high frequency genera tors Keep in mind though that these machines may be used in an environment where other high frequen cy generating machines are operating By taking the following steps high frequency interference into the TOMAHAWK 625 can be minimized 1 Make sure the power supply chassis is connected to a good earth ground The work terminal ground does NOT ground the machin...

Page 10: ...ith a rating less than or equal to 20 micron would be acceptable to use In line filter elements will generally filter the air with little restriction to the airflow until the element 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 TO...

Page 11: ...y 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 ...

Page 12: ...asma cutting uncomplicated This list of design features and advan tages will help you understand the machine s total capabilities so that you can get maximum use from your machine Light weight and portable design for industrial use Continuous control 10 40 amps Reliable touch start mechanism for plasma arc initi ation Rapid arc restrike for fast cutting of expanded metal Input over voltage protect...

Page 13: ...ted life for the TOMAHAWK 625 s elec trode under normal operating conditions is approxi mately 1000 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 Elec...

Page 14: ...e Wait for 5 seconds during this time the output and thermal LEDʼs blinks alternately After 5 seconds the machine is automatically restored and ready to operate 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 operati...

Page 15: ...ine s ON OFF POWER SWITCH to the OFF position Connect the air supply to the machine Turn the main power on and the machine power switch to the ON position The fan will start The pre charge circuit will operate for 3 seconds then the green Power LED will illuminate Attach the work lead clamp to the workpiece before cutting Set the output current control knob to maximum position for higher cutting s...

Page 16: ...een taken 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 trip out initial trigger will be ignored This is a safety feature to prevent the pilot arc from firing unexpectedly or if the torch trigger is inadvertently pressed The other exception is...

Page 17: ... or if there is nothing apparently wrong reset the machine by turning the power switch OFF and then ON again It is possi ble for electrical noise to trip the safety circuit on rare occasions This should not be a regular occur rence If the machine does not reset or continues to trip consult the Troubleshooting Section Use the proper cutting procedures referred to in Procedure Recommendations PILOT ...

Page 18: ...g gestions that may be useful Make sure the air supply to the TOMAHAWK 625 is clean and free of oil Use several extra in line filters if necessary Minimize dross buildup on the nozzle tip by starting the cut from the edge of the plate when possible 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 the...

Page 19: ... jagged cut An optional drag spacer can be attached to the retaining cap to main tain a consistent arc height Contact Cutting Setup Contact Cutting uses special expendable parts that allow the torch to touch the work piece The advan tage of contact cutting is that the torch can touch the work piece steadily dragging it across the surface The disadvantage of contact cutting is the plasma arc is not...

Page 20: ...shield to protect the noz zle from molten metal blow back Refer to the torch parts decal located on your machine or the parts pages at the back of this manual for the specific part numbers required for each of these setups ALWAYS USE GENUINE LINCOLN ELECTRIC ELECTRODES NOZZLES AND EXPENDABLE PARTS FOR THE BEST CUTTING PERFOR MANCE TOMAHAWK 625 www lincolnelectric com ...

Page 21: ...ldew resistant and water repellent It includes a convenient side pocket to hold the plasma torch K2886 1 Plasma Circle Cutting Kit For cutting circles from 3 to 33 in diameter 77mm to 838mm TORCHES The following replacement torch is available K2847 1 LC40 Handheld Plasma Torch 20 6m EXPENDABLE PARTS Refer to the torch parts decal located on your machine or the parts pages at the back of this manua...

Page 22: ... before working on equipment Do not touch electrically hot parts ROUTINE 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 2 Every 6 months or so the machine should be cleaned with a low pressure airstream Keeping the machine clean will result in ...

Page 23: ...mptom 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 If you do not understand or are unable to perform the Recommended Course of Action safely contact you local Lincoln Authorized Field Service Facility HOW TO USE TROUBLESHOOTING GUIDE Service and Repair should onl...

Page 24: ...ltage is less than 187Vac Error when the input voltage is greater than 270Vac Error and shutdown when the input air pressure is low Error and shutdown when the retaining cap is not attached properly Normal thermal response due to overheating Safe Mode if trigger is pulled while turning the machine on or attaching consumables with the trigger pulled This shutdown occurs if the machine cuts for more...

Page 25: ...Board E 3 TROUBLESHOOTING E 3 TOMAHAWK 625 Observe all Safety Guidelines detailed throughout this manual 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 CAUTION PROBLEMS SYMPTOMS POSSIBLE CAUSE RECOMMENDED COURSE OF A...

Page 26: ...e when the trigger is pulled and only the POWER LED is lit 1 Turn the output knob to purge zone on the front of the TOMA HAWK 625 If air does not flow then The main gas solenoid assem bly pressure sensor may be faulty Check or replace Possible faulty Control board 2 Remove the handles or barrel of the torch and examine all the con nections 3 Check for proper trigger switch operation Replace the tr...

Page 27: ...sure the air pressure is set correctly 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 5 Possible faulty Inverter board 1 Check the torch consumables to be sure they are in tight not dirty or greasy and in good shape Replace ...

Page 28: ...g to work Cutting arc appears to turn off while cutting 1 Check work lead connection for 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 3 Make sure work piece is clean and dry Remove any scale rust or dross 4 Possible faulty Inverter board 5 Check all connections to Control Board 1 Input vo...

Page 29: ...y Inverter board 1 Turn the power OFF and then ON If torch and consumables are properly installed and they are the correct parts the Red and Yellow LEDʼs should turn off Normal cutting or gouging 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...

Page 30: ...vered by this manual The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels If the diagram is illegible write to the Service Department for a replacement Give the equipment code number S 1 TOMAHAWK 625 WIRING DIAGRAM 045 101 079 045 101 049 6 24 09 ENHANCED DIAGRAM ...

Page 31: ...NOTES TOMAHAWK 625 ...

Page 32: ... 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 de la tierra Ne laissez ni la peau ni des vête ments mouillés entrer en contact avec des pièces sous tension Isolez vous du travail et de la terre Berühren Sie keine stromführenden Teile oder Elektrod...

Page 33: ... gute Be und Entlüftung des Arbeitsplatzes Mantenha seu rosto da fumaça Use ventilação e exhaustão para remover fumo da zona respiratória Turn power off before servicing Desconectar el cable de ali mentación de poder de la máquina antes de iniciar cualquier servicio Débranchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom völlig öffnen Maschine anhalten Não opere co...

Page 34: ...s 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 World s Leader in Welding and Cutting Products ...

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