Page 2 - SAFETY; PERFORMED ONLY BY QUALIFIED INDIVIDUALS.; WARNING; PLASMA CUTTING or GOUGING can be hazardous.
i SAFETY i 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 you pur-chase a...
Page 3 - ii; ELECTRIC AND MAGNETIC FIELDS
ii SAFETY ii FOR ELECTRICALLYpowered equipment. 6.a. Turn off input power using the disconnectswitch at the fuse box before working on theequipment. 6.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s rec-ommendations. 6.c. Ground the e...
Page 4 - NOTES
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
iv SAFETY iv PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la seco...
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
vi vi TABLE OF CONTENTS Page Installation .......................................................................................................................Section A Technical Specifications .......................................................................................................A...
Page 9 - INSTALLATION; THREE PHASE; Weight
A-1 INSTALLATION A-1 RATED OUTPUT OUTPUT RECOMMEND INPUT WIRE AND FUSE SIZES REQUIRED GAS FLOW RATE REQUIRED GAS INLET PRESSURE TECHNICAL SPECIFICATIONS - PRO-CUT 80 Duty Cycle 60% Duty Cycle 100% Duty Cycle Current Range 35-85 Amps Open Circuit Voltage MAX 335 VDC For all plasma cutting application...
Page 10 - SAFETY PRECAUTIONS; Do not touch electrically hot parts.; SELECT PROPER LOCATION; STACKING; DO NOT; use the pull handle on the optional undercar-; TILTING; (1) Make sure the power supply chassis is connected
A-2 INSTALLATION PRO-CUT 80 A-2 Read entire Installation Section before installing thePRO-CUT 80. 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 fuse box and discharge input...
Page 11 - CORD INSTALLATION
A-3 INSTALLATION PRO-CUT 80 A-3 INPUT ELECTRICALCONNECTIONS Before installing the machine, check that input supplyvoltage, phase, and frequency are the same as themachine's voltage, phase, and frequency as specifiedon the machine's rating plate. The Pro-Cut 80 should be connected only by a quali-fie...
Page 12 - FRAME GROUNDING; Failure to do so may result in; while the; USE ON ENGINE DRIVEN POWER SUPPLIES; AC Wave Form Restrictions; * The 230 VAC auxiliaries of Lincoln engine drives; Input Power Restrictions
A-4 INSTALLATION PRO-CUT 80 A-4 FRAME GROUNDING The frame of the Pro-Cut 80 must be properly ground-ed. A ground terminal marked is mounted on thecase bottom directly behind the input power switch forthis purpose. The cable that is sent attached to themachine is connected to this ground terminal. Se...
Page 13 - GAS INPUT CONNECTIONS; Torch Connection
A-5 INSTALLATION PRO-CUT 80 A-5 GAS INPUT CONNECTIONS Supply the PRO-CUT 80 with clean compressed air ornitrogen. • Supply pressure must be between 80 psi(5.6kg/cm 2 ) and 120 psi(8.4kg/cm 2 ). • Pressure gage, located on the front of the machine, should be set to approximately 70 psi(4.9kg/cm 2 ) f...
Page 14 - OPERATION
B-1 OPERATION PRO-CUT 80 B-1 Read and understand this entire section before oper-ating the machine. SAFETY PRECAUTIONS DESCRIPTION The PRO-CUT 80 is a constant current, continuous con-trol plasma cutting power source. It provides superiorand reliable starting characteristics, cutting visibility anda...
Page 15 - 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 16 - CUTTING CAPABILITY; Lincoln; CONSUMABLE LIFE; The expected life for the PRO-CUT 80
B-3 OPERATION B-3 CUTTING CAPABILITY The PRO-CUT 80 is rated at 80 amps, at 60% duty cycle on a 10 minute basis (runs 80 amps for 6 minutes, thenidling for 4 minutes) or 60 amps, at 100% duty cycle (continuous use). If the duty cycle is exceeded, a thermalprotector will shut off the output of the ma...
Page 17 - LIMITATIONS; GAS PRESSURE SETTINGS
B-4 OPERATION B-4 LIMITATIONS Do not exceed the output current and duty cycle ratingof machine. Do not use the PRO-CUT 80 for pipethawing. CONTROLS AND SETTINGS When preparing to cut or gouge, position the machineas close to the work as possible. Make sure you haveall materials needed to complete th...
Page 18 - SAFETY LED
B-5 OPERATION B-5 • H o l d t h e n o z z l e s t a n d o f f 1 / 8 ” ( 3 . 2 m m ) t o 3 / 1 6 ” (4.8mm) above the workpiece during cutting. Do notlet the nozzle touch the work or carry a long arc. • Keep moving while cutting. Cut at a steady speed without pausing. Maintain the cutting speed so tha...
Page 19 - PILOT ARC DISCUSSION; General - In All Cases; Output set below 45 Amps.; Thick Sections of Metal; Output set above 45 Amps.
B-6 OPERATION B-6 PILOT ARC DISCUSSION The PRO-CUT has a smooth, continuous pilot arc.The pilot arc is only a means of transferring the arc tothe workpiece for cutting. Repeated pilot arc starts, inrapid succession, is not recommended as these startswill generally reduce consumable life. Occasionall...
Page 20 - MACHINE INTERFACE; ELECTRIC SHOCK CAN KILL.
B-7 OPERATION B-7 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 ePRO-CUT 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 Pro-Cut's safety circuit. W...
Page 21 - ACCESSORIES; NOZZLES
C-1 ACCESSORIES C-1 ALWAYS USE GENUINE LINCOLNE L E C T R I C E L E C T R O D E S A N DVORTECH ™ NOZZLES • Only Genuine Lincoln Electric consumables yield the best cutting performance for the PRO-CUT 80. • T h e p a t e n t e d V O R T E C H ™ n o z z l e p r o v i d e s a n extra “ kick ” of swirl ...
Page 22 - MAINTENANCE; ELECTRIC SHOCK; LOCATION OF INPUT FILTER CAPACITOR TERMINALS.
D-1 MAINTENANCE D-1 PRO-CUT 80 INPUT FILTER CAPACITORDISCHARGE PROCEDURE 1. Turn off input power or disconnect input power lines. 2. Remove the 5/16" hex head screws from the side and top of the machine and remove wrap-aroundmachine cover. 3. Be careful not to make contact with the capacitor ter...
Page 23 - ROUTINE MAINTENANCE
D-2 MAINTENANCE D-2 ROUTINE MAINTENANCE 1. Keep the cutting or gouging area and the area around the machine clean and free of combustiblematerials. No debris should be allowed to collectwhich could obstruct air flow to the machine. 2. Every 6 months or so, the machine should be cleaned with a low pr...
Page 24 - TROUBLESHOOTING; Step 3. RECOMMENDED COURSE OF ACTION; HOW TO USE TROUBLESHOOTING GUIDE
E-1 TROUBLESHOOTING E-1 PRO-CUT 80 ELECTRIC SHOCK CAN KILL. • T u r n o f f m a c h i n e a t t h e d i s c o n n e c t switch on the front of the machine andremove main power supply connec-tions before doing any troubleshooting. ----------------------------------------------------------------------...
Page 25 - CAUTION; PROBLEMS
E-2 TROUBLESHOOTING E-2 PRO-CUT 80 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 yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting as...
Page 27 - , possible fault in torch and; Check the torch consumables to be; Contact
E-4 TROUBLESHOOTING E-4 PRO-CUT 80 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 yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting as...
Page 28 - Local Lincoln Authorized Field Service Facility
E-5 TROUBLESHOOTING E-5 PRO-CUT 80 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 a...
Page 29 - STATUS BOARD INDICATORS
E-6 TROUBLESHOOTING E-6 PRO-CUT 80 Observe all Safety Guidelines detailed throughout this manual STATUS BOARD INDICATORS SYMPTOM Machine is unresponsive immediately afterpower-up. The Air Low LED is lit The Safety LED is flashing The Safety LED is lit and steady The Thermal LED is lit The “ Ready ” ...
Page 30 - Observe all Safety Guidelines detailed throughout this manual; for technical troubleshooting assistance before you proceed.; I f t h i s h a s o c c u r r e d n u m e r o u s; Make sure that consumables; CONSUMABLE RELATED SAFETY LED; If the Safety LED is LIT AND STEADY, perform the following:
E-7 TROUBLESHOOTING E-7 PRO-CUT 55 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 a...
Page 31 - DIAGRAMS; ram for a particular code is pasted inside; WIRING DIA
F-1 DIAGRAMS F-1 PRO-CUT 80 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diag ram 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 ...
Page 33 - WI; Enhanced Diagram
F-3 DIAGRAMS F-3 PRO-CUT 55 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diag ram 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 ...
Page 35 - DIMENSION PRINT PR
F-5 DIAGRAMS F-5 PRO-CUT 80 16.41 22.50 3.50 13.71 29.50 CC-UF M19195 DIMENSION PRINT PR O-CUT 80
Page 37 - ÇÃ
WARNING AVISO DE PRECAUCION ATTENTION WARNUNG ATEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BEUSED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS I...
