Page 2 - WARNING; SAFETY
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDRENAWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING. Read and understand the following safety highlights. For additional safety information it is strongly recommended that youpurchase a copy of “Saf...
Page 3 - PLASMA ARC can injure.
Refer to http://www.lincolnelectric.com/safety for additional safety information. 4.c. When not cutting or gouging, make certain no part of the elec- trode circuit is touching the work or ground. Accidental contactcan cause overheating and create a fire hazard. 4.d. Do not cut or gouge tanks, drums ...
Page 4 - NOTES
Page 5 - PRÉCAUTIONS DE SÛRETÉ
iv SAFETY iv PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques qui parraissent dans cemanuel aussi bien que les précautions de sûreté générales suiv-antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secouss...
Page 6 - Thank You; Please Examine Carton and Equipment For Damage Immediately
v v Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual...
Page 7 - TABLE OF CONTENTS
TABLE OF CONTENTS Page Installation .......................................................................................................................Section A Technical Specifications .......................................................................................................A-1Safe...
Page 8 - INSTALLATION; TECHNICAL SPECIFICATIONS -TOMAHAWKTM 625; TEMPERATURE RANGES
A-1 INSTALLATION A-1 Weight Including Torch Cable 34.0 lbs. 15.4 kg. INPUT - SINGLE PHASE 50 / 60 HERTZ RATED OUTPUT AT 40° C OUTPUT RECOMMEND INPUT WIRE AND FUSE SIZES REQUIRED GAS FLOW RATE REQUIRED GAS INLET PRESSURE PHYSICAL DIMENSIONS TECHNICAL SPECIFICATIONS -TOMAHAWK™ 625 Standard Voltage Dut...
Page 9 - SAFETY PRECAUTIONS; SELECT PROPER LOCATION; STACKING; INPUT ELECTRICAL CONNECTIONS
A-2 INSTALLATION TOMAHAWK™ 625 A-2 Read entire Installation Section before installing theTOMAHAWK™ 625. SAFETY PRECAUTIONS ELECTRIC SHOCK CAN KILL. • O n l y q u a l i f i e d p e r s o n n e l should install this machine. • Turn the input power OFF at the disconnect switch or f u s e b o x a n d d ...
Page 10 - GAS INPUT CONNECTIONS; OUTPUT CONNECTIONS; Torch
A-3 INSTALLATION TOMAHAWK™ 625 A-3 The following Lincoln engine drives meet these condi-tions when run in the high idle mode: Outback 189, Ranger 225, 250, 250LPG, 305G and305D engine drives. Vantage 300, 400, 500 and Air Vantage engine drives. Some engine drives do not meet these conditions(e.g. Mi...
Page 11 - OPERATION
B-1 OPERATION TOMAHAWK™ 625 B-1 SAFETY PRECAUTIONS DESCRIPTION The TOMAHAWK™ 625 is a constant current, contin-uous control plasma cutting power source. It providessuperior and reliable starting characteristics, cuttingvisibility and arc stability. The control system has asafety mechanism to insure ...
Page 12 - USER RESPONSIBILITY
B-2 OPERATION B-2 USER RESPONSIBILITY Because design, fabrication, erection and cutting vari-ables affect the results obtained in applying this typeof information, the serviceability of a product or struc-ture is the responsibility of the user. Variation such asplate chemistry, plate surface conditi...
Page 13 - CUTTING CAPABILITY; Tomahawk 625 - Cut Capacity Chart
B-3 OPERATION B-3 CUTTING CAPABILITY The TOMAHAWK™ 625 is rated at 40 amps, at 35%duty cycle on a 10 minute basis. If the duty cycle isexceeded, a thermal protector will shut off the outputof the machine until it cools to the normal operatingtemperature. Figure B.1 shows the cut capacity of the TOMA...
Page 14 - CONTROLS AND SETTINGS; LIMITATIONS
CONTROLS AND SETTINGS (Figure B.2) TOMAHAWK™ 625 front command panel. FIGURE B.2 1. Output Current Knob: Potentiometer used to set the output current used during cutting. Refer tothe Technical Specification section for more infor-mation about the machine’s rated current range. Air Purge: The Output ...
Page 15 - CUTTING PROCESS
B-5 OPERATION B-5 5. Air Pressure Gauge and Regulator Knob : Allows regulation and monitoring of the air pressure. Items 6 thru 9 on the back of the TOMAHAWK™625 (See Figure B.3) 6. Fan: Provides machine cooling. When the machine is switched ON, the fan runs continuously. 7. Power Switch: Turns ON /...
Page 16 - TORCH
Direction of Travel 5 - 15 1/16” 10 - 20 Arc Lag Leading Angle Direction of Travel 5 - 15 1/16” 10 - 20 Arc Lag Leading Angle • Use a 5° - 15° leading angle in the direction of the cut. • Finish the cut to be made and release the trigger. • When the trigger is released, the arc will stop. - The gas ...
Page 17 - PROCEDURE RECOMMENDATIONS; General - In All Cases; PILOT ARC DISCUSSION
PROCEDURE RECOMMENDATIONS When properly used, plasma arc cutting is a very eco-nomical process. Improper use will result in a veryhigh operating cost. General - In All Cases • Follow safety precautions as printed throughout this operating manual and on the machine. • If piercing is required, slowly ...
Page 18 - S u g g e s t i o n s f o r E x t r a U t i l i t y f r o m t h e
B-8 OPERATION B-8 S u g g e s t i o n s f o r E x t r a U t i l i t y f r o m t h e TOMAHAWK™ 625 System: 1. Occasionally an oxide layer may form over the tip of the electrode, creating an insulating barrierbetween the electrode and nozzle. This will resultin the tripping of the TOMAHAWK™ 625's safe...
Page 19 - TORCH PART CONFIGURATIONS
B-9 OPERATION B-9 TORCH PART CONFIGURATIONS There are different torch configurations depending onthe cutting or gouging application. Standard Cutting Setup: In the Standard Cutting configuration the nozzle isdesigned not to touch the work piece. The advantageof this cutting method is good visibility...
Page 21 - ACCESSORIES; GENERAL OPTIONS /ACCESSORIES; TORCHES; EXPENDABLE PARTS
C-1 ACCESSORIES C-1 GENERAL OPTIONS /ACCESSORIES The following options/accessories are available foryour Tomahawk Plasma cutter from your local LincolnDistributor. K2377-1 - Small Canvas Cover Protect your machine when not in use. Made fromattractive red canvas that is flame retardant, mildewresista...
Page 22 - MAINTENANCE; PERIODIC MAINTENANCE; THERMAL PROTECTION; ROUTINE MAINTENANCE
D-1 MAINTENANCE D-1 TOMAHAWK™ 625 PERIODIC MAINTENANCE Change consumables as required. THERMAL PROTECTION Thermal Detection Devices protect the machine fromexcessive operating temperatures. Excessive temper-atures may be caused by a lack of cooling air or oper-ating the machine beyond the duty cycle...
Page 23 - TROUBLESHOOTING; CAUTION
E-1 TROUBLESHOOTING E-1 TOMAHAWK™ 625 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 This Troubleshooting ...
Page 24 - PROBLEMS
1. This may be normal. If output is set to maximum a 30 amp circuiti s r e q u i r e d . S e e T e c h n i c a lSpecification page. 2. Install a larger input circuit or turn t h e o u t p u t c o n t r o l t o a l o w e ramperage. 1. Check the input power to be sure it is on. 2. C h e c k t h e p o ...
Page 28 - STATUS BOARD INDICATORS
E-6 TROUBLESHOOTING E-6 TOMAHAWK™ 625 Observe all Safety Guidelines detailed throughout this manual STATUS BOARD INDICATORS SYMPTOM When trigger is pulled Red output LED isBlinking or steady with no air flow. The Green, Red and Yellow LED’s are litand steady. Indicates safety circuit is open. The Th...
Page 29 - DIAGRAMS
F-1 DIAGRAMS F-1 TOMAHAWK™ 625 NOTE: This diagram is for reference only. It may not be accurate for all machines covered 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 Departmen...
