LOKERMANN GRAND CUT 60 User manual

IIMPORTANT: Read this OPERATOR MANUAL together
with PRESCRIPTION AND COMPLIANCE MANUAL before
to use this equipment. In case of loss one of two parts
contact immediately your dealer.
Allow the operator to consult this manual.
USER MANUAL
GRAND
CUT 60

1 INSTALLATION WARNING
2 OVERVIEW
2.1 Features
2.2 Technical Data
2.3 Working Principle
2.4 Duty cycle and Over-heat
2.5 Volt-Ampere Characteristic
3 INSTALLATION & OPERATION
3.1 Layout for the front and rear panel
3.2 Installation & Operation
3.3 Operation environment
3.4 Operation Notices
4 LKM CUT 60 TORCH
5 MAINTENANCE & TROUBLESHOOTING
5.2 Cutting gun maintenance
5.3 Electrical schematic drawing
CONTENT
5.1 Troubleshooting Principle

This machine is certified according to 60974-10:2014 Arc Welding Equipment
Part 10: Electromagnetic compatibility (EMC) requirement and the EUT belongs to
Group 2 Class A. WARNING: This Class A equipment is intended for industrial use
and it is not intended for use in residential locations where the elctrical power is
provided by the public low-voltage supply system. There may be potential
difficulties in ensuring electromagnetic compatibility in those locations, due to
conducted as well as radiated disturbances.
WARNING: This equipment does not comply with IEC 61000-3-12. If it is connected
to a public low-voltage system, it is the responsability 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.
Assessment of area
Before installing arc welding equipment the user shall make an assessment of
potential electromagnetic problems in the surrounding area. The following shall be
taken into account:
a) other supply cables, control cables, signalling and telephone cables, above,
below and adjacent to the arc welding equipment;
b) radio and television transmitters and receivers;
c) computer and other control equipment;
d) safety critical equipment, for example guarding of industrial equipment;
e) the health of the people around, for example the use of pacemakers and
hearing aids;
f) equipment used for calibration or measurement;
g) the immunity of other equipment in the environment. The user shall ensure
that other equipment being used in the environment is compatible. This may
require additional protection measures;
h) the time of day that welding or other activities are to be carried out.
The size of the surrounding area to be considered will depend on the structure of
the building and other activities that are taking place. The surrounding area may
extend beyond the boundaries of the premises.
Methods of reducing emissions
Public supply system
Arc welding equipment should be connected to the public supply system
according to this manual recommendations. If interference occurs, it may be
necessary to take additional precautions such as filtering of the public supply system.
Consideration should be given to shielding the supply cable of permanently
installed arc welding equipment, in metallic conduit or equivalent. Shielding should
be electrically continuous throughout its length. The shielding should be connected
to the welding power source so that good electrical contact is maintained
between the conduit and the welding power source enclosure.
1
Installation
warning

Welding cables
The welding cables should be kept as short as possible and should be positioned
close together, running at or close to the floor level.
Equipotential bonding
Bonding of all metallic objects in the surrounding area should be considered.
However, metallic objects bonded to the work piece will increase the risk that the
operator could receive an electric shock by touching these metallic objects and
the electrode at the same time. The operator should be insulated from all such
bonded metallic objects.
Earthing of the workpiece
Where the workpiece is not bonded to earth for electrical safety, nor connected
to earth because of its size and position, for example, ship’s hull or building
steelwork, a connection bonding the workpiece to earth may reduce emissions in
some, but not all instances. Care should be taken to prevent the earthing of the
workpiece increasing the risk of injury to users or damage to other electrical
equipment. Where necessary, the connection of the workpiece to earth should
be made by a direct connection to the workpiece, but in some countries where
direct connection is not permitted, the bonding should be achieved by suitable
capacitance, selected according to national regulations.
Screening and shielding
Selective screening and shielding of other cables and equipment in the surrounding
area may alleviate problems of interference. Screening of the entire welding area
may be considered for special applications.

2.1
Features Important Safety Precautions
OPERATION AND MAINTENANCE OF PLASMA ARC EQUIPMENT
CAN BE DANGEROUS TO YOUR HEALTH.
- Plasma arc cutting produces intense electric and magnetic emissions that may
interfere with the proper function of cardiac pacemakers, hearing aids, or other
electronic health equipment. Persons who work near plasma arc cutting
applications should consult their medical health qualified technician and the
manufacturer of the health equipment to deter- mine whether a hazard exists.
- To prevent possible injury, read, understand and follow all warnings, safety
precautions and instructions before using the equipment.
GASES AND FUMES
Gases and fumes produced during the plasma cutting process can be dangerous
and hazardous to your health.
- Keep all fumes and gases from the breathing area. Keep your head out of the
cutting fume plume.
- Use an air-supplied respirator if ventilation is not adequate to remove all fumes
and gases.
- The kinds of fumes and gases from the plasma arc depend on the kind of metal
being used, coatings on the metal, and the different processes.
- Use special equipment, such as water or down draft cutting tables, to capture
fumes and gases.
- Do not use the plasma torch in an area where combustible or explosive gases
or materials are located.
- Phosgene, a toxic gas, is generated from the vapors of chlorinated solvents and
cleansers. Remove all sources of these vapors.
ELECTRIC SHOCK
Electric Shock can injure or kill. The plasma arc process uses and produces high
voltage electrical energy. This electric energy can cause severe or fatal shock to
the operator or others in the workplace.
- Never touch any parts that are electrically “live” or “hot.”
- Wear dry gloves and clothing. Insulate yourself from the work piece or other
parts of the cutting circuit.
- Repair or replace all worn or damaged parts.
- Extra care must be taken when the workplace is moist or wet.
- Disconnect power source before performing any service or repairs.
- Read and follow all the instructions in the Operating Manual.

This machine is certified according to 60974-10:2014 Arc Welding Equipment
Part 10: Electromagnetic compatibility (EMC) requirement and the EUT belongs to
Group 2 Class A. WARNING: This Class A equipment is intended for industrial use
and it is not intended for use in residential locations where the elctrical power is
provided by the public low-voltage supply system. There may be potential
difficulties in ensuring electromagnetic compatibility in those locations, due to
conducted as well as radiated disturbances.
WARNING: This equipment does not comply with IEC 61000-3-12. If it is connected
to a public low-voltage system, it is the responsability 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.
Assessment of area
Before installing arc welding equipment the user shall make an assessment of
potential electromagnetic problems in the surrounding area. The following shall be
taken into account:
a) other supply cables, control cables, signalling and telephone cables, above,
below and adjacent to the arc welding equipment;
b) radio and television transmitters and receivers;
c) computer and other control equipment;
d) safety critical equipment, for example guarding of industrial equipment;
e) the health of the people around, for example the use of pacemakers and
hearing aids;
f) equipment used for calibration or measurement;
g) the immunity of other equipment in the environment. The user shall ensure
that other equipment being used in the environment is compatible. This may
require additional protection measures;
h) the time of day that welding or other activities are to be carried out.
The size of the surrounding area to be considered will depend on the structure of
the building and other activities that are taking place. The surrounding area may
extend beyond the boundaries of the premises.
Methods of reducing emissions
Public supply system
Arc welding equipment should be connected to the public supply system
according to this manual recommendations. If interference occurs, it may be
necessary to take additional precautions such as filtering of the public supply system.
Consideration should be given to shielding the supply cable of permanently
installed arc welding equipment, in metallic conduit or equivalent. Shielding should
be electrically continuous throughout its length. The shielding should be connected
to the welding power source so that good electrical contact is maintained
between the conduit and the welding power source enclosure.
FIRE AND EXPLOSION
Fire and explosion can be caused by hot slag, sparks, or the plasma arc.
- Be sure there is no combustible or flammable material in the workplace.
Any material that cannot be removed must be protected.
- Ventilate all flammable or explosive vapors from the workplace.
- Do not cut or weld on containers that may have held combustibles.
- Provide a fire watch when working in an area where fire hazards may exist.
- Hydrogen gas may be formed and trapped under aluminum workpieces when
they are cut underwater or while using a water table. DO NOT cut aluminum
alloys underwater.
- water table unless the hydrogen gas can be eliminated or dissipated. Trapped
hydrogen gas that is ignited will cause an explosion.
NOISE
Noise can cause permanent hearing loss. Plasma arc processes can cause noise
levels to exceed safe limits. You must protect your ears from loud noise to prevent
permanent loss of hearing.
- To protect your hearing from loud noise, wear protective ear plugs and/or ear
muffs. Protect others in the workplace.
- Noise levels should be measured to be sure the decibels (sound) do not
exceed safe levels.
PLASMA ARC RAYS
Plasma Arc Rays can injure your eyes and burn your skin. The plasma arc process
produces very bright ultra violet and infrared light. These arc rays will damage your
eyes and burn your skin if you are not properly protected.
- To protect your eyes, always wear a cutting helmet or shield. Also always wear
safety glasses with side shields, goggles or other protective eye wear.
- Wear cutting gloves and suitable clothing to protect your skin from the arc rays
and sparks.
- Keep helmet and safety glasses in good condition. Replace lenses when
cracked, chipped or dirty.
- Protect others in the work area from the arc rays. Use protective booths,
screens or shields.

- IGBT module inverter technology for smooth, stable output, increased reliability .
- Microprocessor control system for superio & dynamic arc characteristics.
- Protected external air regulator with water trap/ filter for easy
adjustment & servicing.
- Non HF arc starting system for increased reliability and low EMF pollution.
- Automatic pilot arc control system for increased cutting capability, especially
for discontinuous cutting.
- Strong environmental protection againt moisture,
- Intelligent protection system protects plasma torch from damage.
- Air flow manual activation switch to set & test air pressure.
2
Overview
2.1
Features
2.2
Technical
Data
Models
Parameters GRAND CUT 60
Rated input voltage（V） 3-380V/400V/440V±10%
50/60Hz
Rated input current（A） 18
Rated input power（KW） 7.8
Cutting current adjustment range
（A） 20～60
No-load voltage (V) 450V
Duty cycle（40℃ 10minutes）
100% 60A
The max. cutting thickness to Carbon
steel（mm） ≤30
Optimal cutting
thickness (mm)
Carbon steel ≤30
Stainless steel ≤20
Aluminum ≤15
Cuprum ≤10
Dimensions（mm） 710*280*460
Protection class IP23
Insulation class H
Net weight (kg)） 25
Cooling method AF

The working principle of GRAND CUT 60 is shown as the following figure.
Three-phase 380V line frequency (50/60 Hz) AC is rectified into DC, then it is
converted to medium frequency AC (about 20 KHz) by inverter device
(discrete IGBT), after reducing voltage by medium transformer
(the main transformer) and rectified by medium frequency rectifier (fast recovery
diode), and is outputted by inductance filtering. The circuit adopts current
feedback control technology to insure current output stably. Meanwhile, the
cutting current parameter can be adjusted continuously and steplessly to meet
with the requirements of cutting craft.
2.3
Working
Principle
Rectify Inverter
Medium
frequency
transformer
Medium
frequency
rectify
Hall device
Current positive-
feedback control
Three-phase, AC DC AC DC
380V，50Hz
AC DC
The letter “X” stands for Duty Cycle, which is defined as the portion of the time an
air plasma cutting machine can cut continuously with it’s rated output current
within a certain time cycle (10 minutes). If the plasma cutter is overheating, the
IGBT over-heat protection sensing will send a signal to the plasma cutter control
unit to cut the output cutting current OFF and light the over-heat pilot lamp on the
front panel. In that case, the machine should not be cutting for 10-15 minutes to
cool down with the fan running. When operating the machine again, the cutting
output current or the duty cycle should be reduced.
2.4
Duty
cycle
and
Over-heat

2.5
Volt-Ampere
Charac-
teristic CUT series of Air Plasma Cutting machines has excellent volt-ampere characteristic.
Referring to the following graph. The relation between the rated loading voltage
U2 and welding current I2 is as follows:
When I2≤600A，U2＝80＋0. 4 I2（V）；When 165A<I2≤500A，U2＝130＋0. 1 I2（V）；
When I2 >500A，U2＝180 (V).
67
34
10
0 600 I2（A）
U2（V）
Working
point
Volt-ampere characteristic The relation between the
conventional loading
voltage and welding current
The relation between the
Conventional loading
voltage and cutting current
Installation & Operation
3
Installation
&
Operation
3.1
Layout for
the front and
rear panel

(1) Plasma Torch Euro/ Central Connector.
(2) Earth Lead Connection Socket.
(3) Cutting Current Control Knob.
(4) Power Indicator: Lights when input power connected and machine
switched on.
(5) Alarm Indicator. *
(6) Torch System Error Indicator. *
(7) Cutting Power Indicator: Lights when cutting power circuit activated .
(8) Air Control Run/Set Switch. *
(9) Air Filter Condensate Drain Tube.
(10) Air Pressure Regulator Outlet Pressure Gauge.
(11) Compressed Air Inlet.
(12) Air Pressure Regulator Knob.
(13) Mains Cable: Connected to the appreciate power supply.
(14) Power Switch: Turn on or off the power source.
(15) Air Condensate Filter/Trap Bowl.
*Denotes more detailed explanation of function to follow.
Further Controls Explained
Alarm Indicator (5)
Lights when over voltage, over current or electrical overheating (due to
exceeding duty cycle) is detected and protection is activated. When protection is
activated, welding output will be disabled until the safety system senses the
overload has reduced sufficiently and indicator lamp goes out. May also trigger
if machine experiences an internal power circuit failure.
Torch System Error Indicator (6 )
Lights when issue with torch system or air supply detected and cutting output is
disabled as a result. Flashing light means that torch shield cap is not installed.
Continuous light means likely damaged or missing torch consumables or insufficient
air pressure supply to the torch.
4
6
5
7
3
8

3.2
Installation
& Operation Compressed Air Testing/Setting Switch (8)
When positioned as ‘set’ compressed air control valve is open continuously.
This is useful for testing and setting the air pressure without having to activate the
trigger circuit. ‘Run’ posit-ion is normal operation.
Electrical Connection
The CUT series is designed to operate on a 3 phase 380-400-440V
AC power supply.
Operating with a lower current rated supply circuit will reduce the rated maximum
output and duty cycle performance.
Compressed Air Requirements
A reliable and consistent supply of clean dry compressed air is essential for proper
operation. Although the machine contains its own internal air supply filtration
system it is recommended the compressed air supply should have external filtration
in the line feeding the machine, both a standard water trap (sintered bronze filter)
and also a coalescing filter (for oil in air).The air requirement is a minimum of
140 l/min Free Air Delivery (FAD) at 75psi pressure. This normally means the
compressor must be a belt drive model or if a direct drive it must have a motor
power of 2.5HP or greater. The air must be dry and free of oil and moisture
(normally a symptom of older, worn out compressors). The air hose must also be of
sufficient size (3/8”/10mm minimum) to supply the machine.
Basic Operation
1 Connect the earth cable quick connector to the earth connection socket.
Connect the earth clamp to the work piece. Contact with the work piece must
be firm contact with clean, bare metal, with no corrosion, paint or scale at the
contact point.
2 Connect the plasma torch to the machine central connector ensuring the
collar is done up firmly.
3 Connect the machine to suitable mains power using the mains input power
lead. Switch the mains power switch to ‘on’ to power up the machine.
4 Connect the compressed air supply to the filter/ regulator inlet.
Check the air pressure. Trigger the air flow using the ‘set’ function,
check the air pressure again and adjust if necessary. Return the switch to
‘run’ position.
5 Select the output current using the current control knob.
You are now ready to plasma cut!

Note:
- The alarm lamp on when cutting, it is needed to loose the switch of the torch
until the alarm release, then press on the switch to start cutting again.
- In the automatic gas test and examine, press on the cutting torch, there will no
reflection.
- After a long usage, the surface of the electrode and nozzle will have Oxidation
reaction. Please replace the electrode and nozzle, For The alarm lamp will on
when install the shield cup, and stop working,
3.3
Operation
environment
▲ Height above sea level ≤1000 M
▲ Operation temperature range -10 ～+40°C
▲ Air relative humidity is below 90 %( 20°C)
▲ Preferable site the machine some angles above the floor level, the maximum
angle does not exceed 15 ℃.
▲ Protect the machine against heavy rain and against direct sunshine.
▲ The content of dust, acid, corrosive gas in the surrounding air or substance cannot
exceed normal standard.
▲ Take care that there is sufficient ventilation during welding. There must be at least
Cutting Operation
30cm free distance between the machine and wall.

PLASMA TORCH LKM CUT 60 12MT CENTRAL ADAPTER
CUTTING COMPASS(SUITABLE ONLY WITH SPACER SERIES)
PLASMA TORCH LKM CUT 60 6MT CENTRAL ADAPTER
DESCRIPTION
24006
24008
22549
Further Controls Explained
Alarm Indicator (5)
Lights when over voltage, over current or electrical overheating (due to
exceeding duty cycle) is detected and protection is activated. When protection is
activated, welding output will be disabled until the safety system senses the
overload has reduced sufficiently and indicator lamp goes out. May also trigger
if machine experiences an internal power circuit failure.
Torch System Error Indicator (6
)
Lights when issue with torch system or air supply detected and cutting output is
disabled as a result. Flashing light means that torch shield cap is not installed.
Continuous light means likely damaged or missing torch consumables or insufficient
air pressure supply to the torch.
▲ Read Section §1 carefully before starting to use this equipment.
▲Connect the ground wire with the machine directly.
▲ Ensure that the input is three-phase: 50/60Hz, 380-400-440V ±10%.
▲Before operation, none concerned people should not be around the working
area and especially children. Do not watch the arc in unprotected eyes.
▲ Ensure good ventilation of the machine to improve Duty Cycle.
▲ Turn off the engine when the operation finished for energy consumption
efficiency.
▲When power switch shuts off protectively because of failure. Don’t restart it
until problem is resolved. Otherwise, the range of problem will be extended.
▲In case of problems, contact your local dealer if no authorized maintenance
staff is available!
3.4
Operation
Notices
CODE
4
LKM Cut 60
Torch

Lokermann S.r.l.
Via Produzione 16/18
37044- Cologna Veneta (VR)- Italy
Phone:[phone]
Website: www.lokermann.eu
IEC 60974-7
Reference numbers are for your convenience only. Data and images are indicative and can be changed without notice.
SPARE PARTS
22535
22537
22536
22532
22534 (40A)
22543 (60A)
22526
22527
22548 (60A)
22529 (40A)
22546 (50A)
22540*
22541*
22542*
22526*
22527*
22548* (60A)
22529 (40A)
22546 (50A)
22553
22554
22527
22540
22541
22544
22526
22527
SPACER DRAG EXTENDED GOUGING***
22540
22541
22557
22556
22524
Torch
Torch spares
Further Controls Explained
Alarm Indicator (5)
Lights when over voltage, over current or electrical overheating (due to
exceeding duty cycle) is detected and protection is activated. When protection is
activated, welding output will be disabled until the safety system senses the
overload has reduced sufficiently and indicator lamp goes out. May also trigger
if machine experiences an internal power circuit failure.
Torch System Error Indicator (6
)
Lights when issue with torch system or air supply detected and cutting output is
disabled as a result. Flashing light means that torch shield cap is not installed.
Continuous light means likely damaged or missing torch consumables or insufficient
air pressure supply to the torch.
4
LKM Cut 60
Torch spares
parts
22547

5.1
Troublesho-
oting
Principle
There are extremely dangerous voltage and power levels present inside this unit.
Do not attempt to diagnose or repair unless you have had training in power
electronics measurement and troubleshooting techniques.
A. Power lamp and temperature lamp on
1. Air flow blocked, check for blocked air flow around the unit and correct c
ondition.
2. Fan blocked, check and correct condition.
3. Unit is overheated, let unit cool down for at least 5 minutes. Make sure the unit
has not been operated beyond Duty Cycle limit, refer to technology parameters
in Section 2.
4. Faulty components in unit, return for repair or have qualified technician repair per
Service Manual.
，
B. Torch fails to ignite the arc when torch switch is activated
1. System is in SET mode change to RUN mode.
2. Faulty torch parts, inspect torch parts and replace if necessary.
3. Gas pressure too high or too low, adjust to proper pressure.
4. Faulty components in unit, return for repair or have qualified technician repair per
Service Manual.
C. No cutting output; torch activated, power source on; gas flows;
fan operates
1. Torch not properly connected to power supply, check that torch leads are
properly connected to power supply.
2. Work cable not connected to work piece, or connection is poor, make sure that
work cable has a proper connection to a clean, dry area of the workpiece.
3. Faulty components in unit, return for repair or have qualified technician repair per
Service Manual.
4. Faulty Torch, return for repair or have qualified technician repair.
D. Low cutting output
1. Incorrect setting of CURRENT (A) control, check and adjust to proper setting.
2. Faulty components in unit, return for repair or have qualified technician repair.
E. Difficult starting
1. Worn torch parts (consumables), shut off input power. Remove and inspect torch
shield cup, tip and electrode. Replace electrode or tip if worn; replace shield cup
if excessive spatter adheres to it.
5
Maintenance
&
Troublesho-
oting

5.1
Cutting gun
maintenance Warning : 1. Check the consumable parts for damage, if worn , replace it.
2. Turn off the power source before check or remove c. utting gun parts.
Note: when operating the torch in a normal condition, a small amount of gas vents
through the gap between the shield cup and the torch handle,
Do not attempt to over tighten the shield cup as irreparable damage to i
nternal components may result.
F. Arc shuts off during operation; arc will not restart when torch
switch is activated.
1. Power Supply is overheated, let unit cool down for at least 5 minutes. Make sure
the unit has not been operated beyond Duty Cycle limit. Refer to Section 2 for
duty cycle specifications.
2. Gas pressure too low, check source for at least 4bar/60psi; adjust as needed. It is
need to open the machine cover.
3 Torch consumables worn, check torch shield cup, tip, starter element, and
electrode; replace asneeded.
4. Faulty components in unit:, return for repair or have qualified technician repair
per Service Manual.
G. No gas flow; the power lamp on; fan operates
1. Gas not connected or pressure too low, check gas connections. Adjust gas
pressure to proper settin
H. Torch cuts but low quality
1. Current (A) control set too low, increase current setting.
2. Torch is being moved too fast across workpiece, reduce cutting speed.
3. Excessive oil or moisture in torch, hold torch 1/8 inch (3 mm) from clean surface
while purging and observe oil or moisture buildup (do not activate torch). If there
are contaminants in the gas, additional filtering may be needed.

5.3
Electrical
schematic
drawing

LOKERMANN Srl,
Via Produzione 16/18, 37044, Cologna Veneta,
(VR)-Italy, Tel: [phone]
[email protected] - www.lokermann.eu