Lincoln Electric TOMAHAWK 1025 User manual

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
I
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
II
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
1
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.

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2
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.

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3
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.

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4
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

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5
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.

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6
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

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7
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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8
Technical Specifications
INPUT
Input Voltage
400V ±15%
Three Phase
Input Power at Rated Output EMC Class
Frequency
50/60Hz
TH1025 4.3kW @ 100% Duty Cycle
7.1kW @ 40% Duty Cycle A
TH1538 7.1kW @ 100% Duty Cycle
13.7kW @ 40% Duty Cycle A
RATED OUTPUT AT 40°C
Duty Cycle
(Based on a 10 min. period)
Output Current Output Voltage
TH1025 100%
60%
40%
40A
50A
60A
96VDC
100VDC
104VDC
TH1538 100%
60%
40%
60A
85A
100A
104VDC
114VDC
120VDC
OUTPUT RANGE
Cutting Current Range Maximum Open Circuit Voltage Pilot Arc Current
TH1025 20 - 60A TH1025 320VDC TH1025 20A
TH1538 20 - 100A TH1538 320VDC TH1538 20A
COMPRESSED AIR or GAS
Required Flow Rate Required Inlet Pressure
TH1025 130 ±20% l/min @ 5.5bar 6.0bar ÷ 7.5bar
TH1538 280 ±20% l/min @ 5.5bar
RECOMMENDED INPUT CABLE AND FUSE SIZES
Fuse (delayed) or Circuit Breaker (“D” characteristic) Size Input Power Cable
TH1025 20A TH1025 4 x 2.5mm
2
TH1538 32A TH1538 4 x 4mm
2
PHYSICAL DIMENSIONS
Height Width Length Weight
TH1025 389mm TH1025 247mm TH1025 510mm TH1025 22kg
TH1538 455mm TH1538 301mm TH1538 640mm TH1538 34kg
Operating Temperature
-10°C to +40°C
Storage Temperature
-25°C to +55°C
WEEE
07/06
English
Do not dispose of electrical equipment together with normal waste!
In observance of European Directive 2012/19/EC on Waste Electrical and Electronic Equipment (WEEE)
and its implementation in accordance with national law, electrical equipment that has reached the end of its
life must be collected separately and returned to an environmentally compatible recycling facility. As the
owner of the equipment, you should get information on approved collection systems from our local
representative.
By applying this European Directive you will protect the environment and human health!
Spare Parts
12/05
Part List reading instructions
Do not use this part list for a machine if its code number is not listed. Contact the Lincoln Electric Service
Department for any code number not listed.
Use the illustration of assembly page and the table below to determine where the part is located for your particular
code machine.
Use only the parts marked "X" in the column under the heading number called for in the assembly page (# indicate
a change in this printing).
First, read the Part List reading instructions above, then refer to the "Spare Part" manual supplied with the machine, that
contains a picture-descriptive part number cross-reference.
Electrical Schematic
Refer to the "Spare Part" manual supplied with the machine.