Lincoln Electric PRO-CUT 25 User manual

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

2
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

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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

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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.

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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

6
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

7
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
0
25
50
75
100
125
150
175
200
2345678910
Metal Thickness (mm)
Recommended Travel Speed
(cm/min)

8
•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.

9
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.

10
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