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IM10020
January, 2011
™
TOMAHAWK 625
For use with machines having Code Number:
11580
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper installation
... and thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before
you act and be careful.
OPERATOR’SꢀMANUAL
Copyright © Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEBꢀSITE: www.lincolnelectric.com
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ii
SAFETY
4.c. When not cutting or gouging, make certain no part of the elec-
trode circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard.
FORꢀELECTRICALLY
powered equipment.
6.a. Turn off input power using the disconnect
switch at the fuse box before working on the
equipment.
4.d. Do not cut or gouge tanks, drums or containers until the proper
steps have been taken to insure that such procedures will not
cause flammable or toxic vapors from substances inside. They
can cause an explosion even though they have been
“cleaned.” For information purchase “Recommended Safe
Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances”, AWSꢀF4.1 from the American Welding Society
(see address above).
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 equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
4.e. Vent hollow castings or containers before heating, cutting or
gouging. They may explode.
PLASMA ARC can injure.
4.f. Do nor fuel engine driven equipment near area where plasma
cutting or gouging.
7.a. Keep your body away from nozzle and
plasma arc.
4.g. Sparks and spatter are thrown from the plasma arc. Wear
safety glasses, ear protection and oil free protective garments
such as leather gloves, heavy shirt, cuffless trousers, high
shoes and a cap over your hair. Wear ear plugs when cutting
or gouging out of position or in confined places. Always wear
safety glasses with side shields when in a cutting or gouging
area.
7.b. Operate the pilot arc with caution. The pilot arc is capable of
burning the operator, others or even piercing safety clothing.
4.h. Connect the work cable to the work as close to the cutting or
gouging area as practical. Work cables connected to the build-
ing framework or other locations away from the cutting or
gouging area increase the possibility of the current passing
through lifting chains, crane cables or other alternate circuits.
This can create fire hazards or overheat lifting chains or
cables until they fail.
ELECTRIC AND MAGNETIC
FIELDS
4.I. Read and follow NFPA 51B “ Standard for Prevention During
Welding, Cutting and Other Hot Work”, available from NFPA, 1
Batterymarch Park,PO box 9101, Quincy, Ma 022690-9101.
may be dangerous
8.a. Electric current flowing through any con-
ductor causes localized Electric and Magnetic
Fields (EMF). Cutting or gouging current cre-
ates EMF fields around torch cables and cutting
machines.
8.b. EMF fields may interfere with some pacemakers, so opera-
tors having a pacemaker should consult their physician
before cutting or gouging.
CYLINDER may explode
if damaged.
5.a. Use only compressed gas cylinders contain-
ing the correct gas for the process used and
properly operating regulators designed for the
gas and pressure used. All hoses, fittings, etc.
should be suitable for the application and maintained in good
condition.
8.c. Exposure to EMFꢀfields during cutting or gouging may have
other health effects which are now not known.
8d. All operators should use the following procedures in order to
minimize exposure to EMF fields from the cutting or gouging
circuit:
5.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
8.d.1. Route the torch and work cables together - Secure
them with tape when possible.
5.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
8.d.2. Never coil the torch cable around your body.
8.d.3. Do not place your body between the torch and
work cables. If the torch cable is on your right side,
the work cable should also be on your right side.
• A safe distance from plasma cutting or gouging, arc weld-
ing operations and any other source of heat, sparks,
or flame.
5.d. Never allow any part of the electrode, torch or any other
electrically “hot” parts to touch a cylinder.
8.d.4. Connect the work cable to the workpiece as close as
possible to the area being cut or gouged.
5.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
8.d.5. Do not work next to cutting power source.
5.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
5.g. Read and follow the instructions on compressed gas cylin-
ders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,”available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
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NOTES
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SAFETY
PRÉCAUTIONS DE SÛRETÉ
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
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:
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
Sûreté Pour Soudage A L’Arc
8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on place
la masse sur la charpente de la construction ou d’autres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de lev-
age, câbles de grue, ou autres circuits. Cela peut provoquer
des risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
du corps.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du ray-
onnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
er à l’interrupteur à la boite de fusibles.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan-
talons sans revers, et chaussures montantes.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
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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!
Thank You
CUSTOMER ASSISTANCE POLICY
The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip-
ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln
Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses-
sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor-
mation or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular purpose,
with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or
correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any
warranty with respect to the sale of our products.
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in
applying these types of fabrication methods and service requirements.
for any updated information.
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line Product Registration
- Register your machine with Lincoln Electric either via fax or over the Internet.
• For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.
• For On-Line Registration: Go to our WEBꢀSITE at www.lincolnelectric.com. Choose “Quick Links” and then
“Product Registration”. Please complete the form and submit your registration.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.
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TABLE OF CONTENTS
Page
Installation.......................................................................................................................Section A
Technical Specifications.......................................................................................................A-1
Safety Precautions ...............................................................................................................A-2
Select Proper Location.........................................................................................................A-2
Stacking................................................................................................................................A-2
Tilting....................................................................................................................................A-2
High Frequency Interference Protection...............................................................................A-2
Input Electrical Connections.................................................................................................A-2
Gas Input Connections.........................................................................................................A-3
Output Connections..............................................................................................................A-3
Torch.............................................................................................................................A-3
________________________________________________________________________________
Operation.........................................................................................................................Section B
Safety Precautions ...............................................................................................................B-1
Description ...........................................................................................................................B-1
Preheat Temperature for Plasma Cutting.............................................................................B-1
User Responsibility...............................................................................................................B-2
Operational Features and Controls ......................................................................................B-2
Design Features and Advantages........................................................................................B-2
Cutting Capability .................................................................................................................B-3
Consumable Life ..................................................................................................................B-3
Limitations ............................................................................................................................B-4
Controls and Settings ...................................................................................................B-4, B-5
Cutting Process ............................................................................................................B-5, B-6
Pilot Arc Discussion..............................................................................................................B-7
Procedure Recommendations..............................................................................................B-7
General .........................................................................................................................B-7
Suggestions for Extra Utility from the TOMAHAWK™ 625 System..............................B-8
Torch Part Configuration.............................................................................................B-9, B-10
________________________________________________________________________________
Accessories.....................................................................................................Section C
________________________________________________________________________
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
Routine Maintenance.............................................................................................D-1
Periodic Maintenance............................................................................................D-1
________________________________________________________________________
Troubleshooting..............................................................................................Section E
Safety Precautions.................................................................................................E-1
How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide ...........................................................................E-2 Thru E-6
________________________________________________________________________
Wiring Diagrams..............................................................................................Section F
Wiring Diagram ......................................................................................................F-1
________________________________________________________________________
Parts Lists........................................................................................................Appendix
TOMAHAWK™ 625................................................................................P-626 Series
Torch.............................................................................................................P-210-W
________________________________________________________________________
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A-1
INSTALLATION
TECHNICAL SPECIFICATIONS -TOMAHAWK™ 625
A-1
INPUT - SINGLE PHASE 50 / 60 HERTZ
Standard Voltage
208V, 230V ±10% / 1 / 50 / 60Hz
RATED OUTPUT AT 40° C
CURRENT AMPS
VOLTAGE VOLTS
89.6VDC
91.8VDC
Duty Cycle
100%
60%
24 A
29 A
40 A
96.0VDC
35%
OUTPUT
Current
Range
10-40 Amps
Open Circuit
Voltage
460 VDC
Pilot Current
12 Amps
REQUIRED GAS FLOW RATE
70 PSI @ 125-200 SCFH
( 5 Bar. @ 80±20 LITERS/MIN.)
REQUIRED GAS INLET PRESSURE
80 to 110 PSI
(6 Bar. to 7.5 Bar.)
RECOMMEND INPUT WIRE AND FUSE SIZES
For all plasma cutting applications
Based on U.S. National Electrical Code
Ambient Temperature 30oC or Less
Output AC Input
Fuse
Type S, SO, ST, STO or extra
hard usage input cord
AWG (IEC) Sizes
Input Cord Plug Size
Voltage
at
50/60
Hertz
(Super Lag)
Circuit Breaker
(Delay Type)
1 Ground Wire
#12 (3.3 mm2)
2 Input Supply Wires
#12 (3.3 mm2)
230V-1Ø
40 A
6-50P
30 AMPS
208V-1Ø
PHYSICAL DIMENSIONS
Weight
Including
Torch Cable
Height
Width
Depth
34.0 lbs.
15.4 kg.
15.2 in.
385 mm
8.5 in.
215 mm
18.9 in.
480 mm
TEMPERATURE RANGES
OPERATING TEMPERATURE RANGE
-10°C to +40°C
STORAGE TEMPERATURE RANGE
-10°C to +40°C
TOMAHAWK™ 625
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A-2
A-2
INSTALLATION
Read entire Installation Section before installing the
TOMAHAWK™ 625.
HIGH FREQUENCY INTERFERENCE
PROTECTION
The TOMAHAWK™ 625 employs a touch start mech-
anism for arc initiation which eliminates high frequen-
cy emissions from the machine as compared with
spark gap and solid state type high frequency genera-
tors. Keep in mind, though, that these machines may
be used in an environment where other high frequen-
cy generating machines are operating. By taking the
following steps, high frequency interference into the
TOMAHAWK™ 625 can be minimized
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK CAN KILL.
•
Only qualified personnel
should install this machine.
Turn the input power OFF
at the disconnect switch or
fuse box and discharge
input capacitors before
working inside the equip-
ment.
•
(1) Make sure the power supply chassis is connected
to a good earth ground. The work terminal ground
does NOT ground the machine frame.
(2) Keep the work clamp isolated from other work
clamps that have high frequency.
(3) If the work clamp cannot be isolated, then keep
the clamp as far as possible from other work
clamp connections.
•
•
Do not touch electrically hot parts.
Turn the TOMAHAWK™ 625 Power Switch
OFF when connecting power cord to input
power.
___________________________________________
(4) When the machine is enclosed in a metal building,
several good earth driven electrical grounds
around the periphery of the building are recom-
mended.
SELECT PROPER LOCATION
Place the TOMAHAWK™ 625 where clean cool air
can freely circulate in and out of the side louvers. Dirt,
dust or any foreign material that can be drawn into the
machine should be kept at a minimum. Failure to
observe these precautions can result in excessive
operating temperatures and nuisance shutdown of the
machine.
Failure to observe these recommended installation
procedures may cause improper function of the TOM-
AHAWK™ 625 or possibly even damage to the control
system or power supply components.
INPUT ELECTRICAL CONNECTIONS
A source of clean, dry air or nitrogen must be supplied
to the TOMAHAWK™ 625 when using external air
supply. Oil in the air is a severe problem and must be
avoided. The supply pressure must be between 80
and 150 psi. The flow rate is approximately 4.0 cfm
(113 l/min.). Failure to observe these precautions
could result in excessive operating temperatures or
damage to the torch.
The TOMAHAWK™ 625 is rated for 208VAC and
230VAC input voltage. Before installing the machine,
check that input supply voltage, phase, and frequency
are the same as the machine's voltage, phase, and
frequency as specified on the machine's rating plate.
• The TOMAHAWK™ 625 should be connected only
by a qualified electrician. Installation should be
made in accordance with local codes.
STACKING
For use on engine drives, keep in mind the above
input draw restrictions and the following precaution.
The TOMAHAWK™ 625 cannot be stacked.
The TOMAHAWK™ 625 can be operated on engine
driven generators as long as the 230 volt auxiliary
meets the following conditions:
TILTING
The TOMAHAWK™ 625 must be placed on a stable,
level surface so it will not topple over.
• The AC waveform peak voltage is below 400 volts.
• The AC waveform frequency is between 45 and 65
Hz.
• The RMS voltage of the AC waveform is always
greater than 208VAC.
TOMAHAWK™ 625
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A-3
A-3
INSTALLATION
The following Lincoln engine drives meet these condi-
tions when run in the high idle mode:
Outback 189, Ranger 225, 250, 250LPG, 305G and
305D engine drives.
NOTE: When using nitrogen gas from a cylinder, the
cylinder must have a pressure regulator.
•
•
Maximum psi from a nitrogen gas cylinder to
the TOMAHAWK™ 625 regulator should
never exceed 110 psi.
Install a hose between the nitrogen gas cylin-
der regulator and the TOMAHAWK™ 625 gas
inlet.
Vantage 300, 400, 500 and Air Vantage engine drives.
Some engine drives do not meet these conditions
(e.g. Miller Bobcats, etc). Operation of the TOMA-
HAWK™ 625 is not recommended on engine drives
not conforming to these conditions. Such combina-
tions may overvoltage the TOMAHAWK™ 625 power
source.
.
WARNING
GAS INPUT CONNECTIONS
(External Air Supply)
CYLINDER could explode if dam-
aged.
• Keep cylinder upright and
chained to a fixed support.
• Keep cylinder away from areas
where it could be damaged.
Supply the TOMAHAWK™ 625 with clean com-
pressed air or nitrogen.
•
•
Supply pressure must be between 80 psi
and 110 psi.
Flow rate should be approximately 125 - 200
SCFH (80 ±20 L/min).
• Never lift machine with cylinder attached.
•
•
•
Never allow the cutting torch to touch the
cylinder.
Keep cylinder away from live electrical
parts.
Maximum inlet pressure 110 psi.
NOTE: Oil in the air supply to the TOMAHAWK™ 625
can cause severe problems. Use only a clean
air supply.
------------------------------------------------------------------------
OUTPUT CONNECTIONS
•
Compressed gas can be supplied either through the air
fitting supplied with the machine or through the 1/4-19
BSPP thread at the rear of the machine. To use the air
fitting supplied with the machine (packaged in the con-
sumable kit), apply teflon tape to the fitting threads and
install the fitting in the port at the rear of the machine.
• If compressed air is being used, it is highly recom-
mended that an in line filter be installed in the air
supply line ahead of the air connection to the TOMA-
HAWK™ 625.
Torch
The TOMAHAWK™ 625 is sent from the factory with
a cutting torch and work clamp included. 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.
• A standard nominal 5 micron in line filter is recom-
mended; however, for optimum performance, select
a prefilter with a 3 micron absolute rating.
If these filter ratings are unavailable, anything with a
rating less than, or equal to, 20 micron would be
acceptable to use. In line filter elements will generally
filter the air with little restriction to the airflow until the
element is about 75% contaminated. After this point,
there will be a noticeable pressure drop in the line.
Filter elements should be replaced when a pressure
drop of 8-10 psi is indicated; however, for optimum
performance of the TOMAHAWK™ 625, the filter ele-
ment should be replaced at or before the pressure
drop reaches 8 psi. Be sure to select a filter that will
accommodate the necessary flow rating for the TOM-
AHAWK™ 625 as specified in the Installation section
of this instruction manual under the Gas Input
Connections heading.
TOMAHAWK™ 625
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B-1
B-1
OPERATION
DESCRIPTION
SAFETY PRECAUTIONS
WARNING
The TOMAHAWK™ 625 is a constant current, contin-
uous control plasma cutting power source. It provides
superior and reliable starting characteristics, cutting
visibility and arc stability. The control system has a
safety mechanism to insure that the nozzle and elec-
trode are in place before cutting or gouging. This is
extremely important due to the high voltages involved.
ELECTRIC SHOCK
can kill.
• Do not touch electrically live parts
or electrode with skin or wet
clothing.
The TOMAHAWK™ 625 comes standard with an air
regulator and pressure gauge. The machine also
comes with an input power cord, Hand-held torch with
a 20' cable length. Consumables are included with
each TOMAHAWK™ 625 purchase so that cutting can
begin right out of the box. Consumables can also be
ordered as individual packages.
• Insulate yourself from work and
ground.
• Always wear dry insulating
gloves.
FUMES AND GASES
can be dangerous.
The TOMAHAWK™ 625 initiates the plasma arc with
a simple, yet reliable, touch start mechanism. This
system eliminates many of the failure problems asso-
ciated with hi-frequency start systems.
• Keep your head out of fumes.
• Use ventilation or exhaust to
remove fumes from breathing
zone.
PREHEAT TEMPERATURE FOR
PLASMA CUTTING
WELDING, CUTTING and
GOUGING SPARKS
can cause fire or explosion
Preheat temperature control is not necessary in most
applications when plasma arc cutting or gouging.
Preheat temperature control may be necessary on high
carbon alloy steels and heat treated aluminum for crack
resistance and hardness control. Job conditions, pre-
vailing codes, alloy level, and other considerations may
also require preheat temperature control. The following
minimum preheat temperature is recommended as a
starting point. Higher temperatures may be used as
required by the job conditions and/or prevailing codes.
If cracking or excessive hardness occurs on the cut
face, higher preheat temperature may be required. The
recommended minimum preheat temperature for plate
thickness up to 1/2" (12.7mm) is 70°F (21.1°C).
• Keep flammable material away.
• Do not weld, cut or gouge on
containers that have held combustibles.
ARC RAYS
can burn.
• Wear eye, ear and body
protection.
PLASMA ARC
can injure
• Keep your body away from nozzle
and plasma arc.
• Operate the pilot arc with caution. The
pilot arc is capable of burning the
operator, others or even piercing
safety clothing.
Observe additional Safety Guidelines detailed in
the beginning of this manual.
TOMAHAWK™ 625
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B-2
B-2
OPERATION
USER RESPONSIBILITY
Because design, fabrication, erection and cutting vari-
ables affect the results obtained in applying this type
of information, the serviceability of a product or struc-
ture is the responsibility of the user. Variation such as
plate chemistry, plate surface condition (oil, scale),
plate thickness, preheat, quench, gas type, gas flow
rate and equipment may produce results different than
those expected. Some adjustments to procedures
may be necessary to compensate for unique individ-
ual conditions. Test all procedures duplicating actual
field conditions.
DESIGN FEATURES AND
ADVANTAGES
The TOMAHAWK™ 625 design makes plasma cutting
uncomplicated. This list of design features and advan-
tages will help you understand the machine's total
capabilities so that you can get maximum use from
your machine.
- Light weight and portable design for industrial use.
- Continuous control, 10 - 40 amps.
- Reliable touch start mechanism for plasma arc initi-
ation.
- Rapid arc restrike for fast cutting of expanded metal.
- Input over voltage protection.
- Bright 3.0 second timed pilot arc.
- Purge section on output dial.
- Air regulator and pressure gage included.
- Internal water separator included.
- Parts-in-Place mechanism to detect proper installa-
tion of consumables and torch.
- Preflow/Postflow timing. Preflow is eliminated if arc
is re-initiated in Postflow.
- Thermostatic Protection.
- Solid state over-current protection.
- Unique electrode and nozzle design for optimum
cooling and long life.
TOMAHAWK™ 625
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B-3
B-3
OPERATION
CONSUMABLE LIFE
CUTTING CAPABILITY
The expected life for the TOMAHAWK™ 625's elec-
trode under normal operating conditions is approxi-
mately 1000 starts/cuts. An erosion of .060" 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.
The TOMAHAWK™ 625 is rated at 40 amps, at 35%
duty cycle on a 10 minute basis. If the duty cycle is
exceeded, a thermal protector will shut off the output
of the machine until it cools to the normal operating
temperature.
Figure B.1 shows the cut capacity of the TOMA-
HAWK™ 625 when cutting mild steel. (The graph
plots cut thickness vs. torch travel speed with a torch
standoff of 0.15".)
It is recommended that consumables be replaced in
complete sets. (Example: Electrode and Nozzle). This
will maximize the performance of the TOMAHAWK™
625 system.
Figure B.1
T
M
A
W
6
1
M
70890
T
m
a
a
6
5
-
t
a
a
i
C
a
t
Tomahawk 625 - Cut Capacity Chart
90
80
70
60
50
40
30
20
10
0
0.125
0.25
0.375
0.5
0.625
0.75
Metal Thickness (inches)
TOMAHAWK 625
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B-4
B-4
OPERATION
LEDs
Output Thermal
Description
LIMITATIONS
(Red)
On
On
(Yellow)
Off
On
Do not exceed output current and duty cycle rating of
machine. Do not use the TOMAHAWK™ 625 for pipe
thawing.
The cutting torch is energized.
Part in place error: the retaining
cap is not properly Attached.
If the arc turns off while cutting using low input volt-
age, that is below 208V, lower the air pressure by
adjusting the regulator knob.
To restore the machine:
• Install the torch retaining cap
firmly in place.
• Wait for 5 seconds; during this
time the output and thermal
LED’s blinks alternately.
When using with the Outback 180, gouging is not rec-
ommended.
• After 5 seconds the machine is
automatically restored and ready
to operate.
CONTROLS AND SETTINGS
(Figure B.2)
Off
On
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 pos-
sible.
TOMAHAWK™ 625 front command panel.
FIGURE B.2
3
w
e
.
A
4
WK
1
4
1
25
4
Off
Blink
Power undervoltage error: the
machine is disabled. When the
power returns to the correct range,
the machine will restart automati-
cally.
10
5
40
V
A
A
2
1MPa = 145 psi
6 2 5
3
TOMAHAWK
Blink Off
Low air pressure error.
www.lincolnelectric.com
To check / adjust the air pressure
(see recommended values in the
Technical Specifications of this
manual):
1. Output Current Knob: Potentiometer used to set
the output current used during cutting. Refer to
the Technical Specification section for more infor-
mation about the machine’s rated current range.
• Put the machine in Purge mode
[1].
• Check and adjust the air pres-
sure using the pressure gauge
and air pressure regulator knob
[6].
• If necessary, check and adjust
also the inlet air pressure by
adjusting the external compres-
sor.
Air Purge: The Output Current Knob completely
rotated counterclockwise enables the air purge
function. A five minute timeout stops the purge
function; this will occur only if the Output Current
Knob remains in the purge mode for an extended
time.
2. Power ON/OFF green LED: Illuminates when
the machine is ON.
3. Output red LED: See the following table.
4. Thermal yellow LED: See the following table.
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B-5
B-5
OPERATION
Turn the machine's ON/OFF POWER SWITCH to the
OFF position.
5. Air Pressure Gauge and Regulator Knob: Allows
regulation and monitoring of the air pressure.
• Connect the air supply to the machine.
Items 6 thru 9 on the back of the TOMAHAWK™
625 (See Figure B.3)
• Turn the main power on and the machine power
switch to the ON position.
- The fan will start.
6. Fan: Provides machine cooling. When the machine
is switched ON, the fan runs continuously.
- The pre-charge circuit will operate for 3 seconds,
then the green "Power" LED will illuminate.
7. Power Switch: Turns ON / OFF the input power to
the machine.
• Attach the work lead clamp to the workpiece before
cutting.
8. Input cable: Connects unit to the input power.
• Set the output current control knob to maximum
position for higher cutting speed and less dross for-
mation. Reduce the current, if desired to reduce the
kerf (cut) width, heat affected zone, or travel speed
as required.
9. Air Inlet: External Air operating mode only.
Compressed Air Connection.
WARNING
Note: If the circuit breaker trips while cutting at high-
er amperages - reduce the cutting amperage
on the unit, or provide an input circuit with
higher current capacity.
Clean, dry air must be supplied to the machine. A
pressure setting above 110 PSI (7.5 bar) could
damage the torch. Failure to observe these pre-
cautions could result in excessive operating tem-
peratures or damage to the torch.
• Rotate the output knob into the purge zone to check
or set the gas pressure. Pull the pressure regulator
cap out and turn it to set the pressure.
------------------------------------------------------------------------
CUTTING PROCESS
- Adjust the gas regulator for 75-80 PSI (0.50-0.55
MPa).
When preparing to cut, position the machine as close
to the work as possible. Make sure to have all materi-
als needed to complete the job and have taken all
safety precautions. It is important to follow these oper-
ating steps each time the machine is used.
- Turn the output knob out of the purge zone.
- The gas will immediately turn off. The pressure
gage may show an increase in pressure after the
air turns off but this is normal. Do NOT reset the
pressure while the air is NOT flowing.
FIGURE B.3
7
6
9
8
6
7
8
9
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B-6
B-6
OPERATION
• When ready to cut, place the torch near the work,
make certain all safety precautions have been
taken and pull the trigger.
5 - 15
Leading Angle
- 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 trip out, initial trigger
will be ignored. This is a safety feature to prevent
the pilot arc from firing unexpectedly or if the
torch trigger is inadvertently pressed. The other
exception is if the machine is in postflow, then
the preflow time is skipped and the pilot arc will
start immediately.)
Direction of Travel
1/16”
10 - 20
Arc Lag
•
Use a 5° - 15° leading angle in the direction of the cut.
- The pilot arc will run for 3.0 seconds and shut off
unless the arc is brought in contact with the work
and the arc is transferred. Avoid excessive pilot
arc time by transferring the arc to the workpiece
quickly. This will extend consumable life.
• Finish the cut to be made and release the trigger.
• When the trigger is released, the arc will stop.
- When the arc is brought within 1/8” - 1/4" from
the work piece: the arc will transfer, the current
will ramp to the setting on the control panel, and
the cut can last indefinitely (or until the duty
cycle of the TOMAHAWK™ 625 is exceeded).
- The gas will continue to flow for 15 seconds of
postflow. If the trigger is activated within this time
period, the pilot arc will immediately restart.
• If the dross is difficult to remove, reduce the cutting
speed. High speed dross is more difficult to remove
than low speed dross.
• Pierce the work piece by slowly lowering the torch
onto the metal at a 300 angle away from the opera-
tor. This will blow the dross away from the torch
tip. Slowly rotate the torch to vertical position as
the arc becomes deeper.
WARNING
ELECTRIC SHOCK CAN KILL.
• Turn off machine at the disconnect
switch on the rear of the machine
before tightening, cleaning or
TORCH AT 300 ANGLE
TO PIERCE
replacing consumables.
----------------------------------------------------------------------------
• Clean spatter and scale from the nozzle frequently.
ROTATE TO
900 ANGLE TO CUT
300
TORCH
• During operation, if the Red and Yellow LED’s light
together:
900
VERTICAL AANGLE
FOR CUTTING
• Check the assembly of the torch consumables. If
they are not properly in place, the machine will not
start. Make sure that the shield cup is hand
tight. Do not use pliers or over tighten.
CUT
• Keep moving while cutting. Cut at a steady speed
without pausing. Maintain the cutting speed so that
the arc lag is 10° to 20° behind the travel direction.
• Check the conditions of 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. Refer to "Suggestions for Extra
Utility from the TOMAHAWK™ 625 system".
• 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 .062”. A green and erratic arc will
indicate definite electrode failure and the electrode
should be replaced immediately.
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B-7
B-7
OPERATION
• Replace the nozzle when the orifice exit is eroded
away or oval shaped.
PROCEDURE RECOMMENDATIONS
When properly used, plasma arc cutting is a very eco-
nomical process. Improper use will result in a very
high operating cost.
• 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. (It is possi-
ble for electrical noise to trip the safety circuit on
rare occasions. This should not be a regular occur-
rence.)
General - In All Cases
• Follow safety precautions as printed throughout this
operating manual and on the machine.
• If the machine does not reset or continues to trip,
consult the Troubleshooting Section.
• If piercing is required, slowly lower the torch at an
angle of about 30° to blow the dross away from
the torch tip and slowly rotate the torch to a ver-
tical position as the arc becomes deeper. This
process will blow a lot of molten metal and
dross. Be careful! Blow the dross away from
the torch, the operator and any flammable
objects.
• Use the proper cutting procedures referred to in
Procedure Recommendations.
PILOT ARC DISCUSSION
The TOMAHAWK™ 625 has a smooth, continuous
pilot arc. The pilot arc is only a means of transferring
the arc to the workpiece for cutting. Repeated pilot arc
starts, in rapid succession, is not recommended as
these starts will generally reduce consumable life.
Occasionally, the pilot arc may sputter or start inter-
mittently. This is aggravated when the consumables
are worn or the air pressure is too high. Always keep
in mind that the pilot arc is designed to transfer the arc
to the workpiece and not for numerous starts without
cutting.
• The nozzle should not be dragged on the metal
surface. A drag spacer is provided to maintain a
consistant touch height. Refer to Touch Parts
Configurations in this Section.
Torch Standoff
The TOMAHAWK™ 625 does not utilize high frequen-
cy starting. When the pilot arc is started, a slight
impulse will be felt in the torch handle. This occur-
rence is normal and is the mechanism which starts the
plasma arc. This impulse can also be used to help
troubleshoot a "no start" condition.
1/16” Standoff
• Where possible, start the cut from the edge of the
work piece.
• Keep moving! A steady speed is necessary. Do
not pause.
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B-8
B-8
OPERATION
Suggestions for Extra Utility from the
TOMAHAWK™ 625 System:
• Set air pressure to recommended setting. A
higher or lower pressure will cause turbulence
in the plasma arc, eroding the orifice of the
nozzle tip.
WARNING
ELECTRIC SHOCK CAN KILL.
• Turn off machine at the disconnect
switch on the rear of the machine
before tightening, cleaning or replacing
• Use only Lincoln consumable parts. These
parts are patented and using any other replace-
ment consumables may cause damage to the
torch or reduce cut quality.
consumables.
----------------------------------------------------------------------------
1. Occasionally an oxide layer may form over the tip
of the electrode, creating an insulating barrier
between the electrode and nozzle. This will result
in the tripping of the TOMAHAWK™ 625's safety
circuit. When this happens turn the power off,
remove the nozzle and electrode and use the elec-
trode to rub against the inside bottom surface of
the nozzle. This will help remove any oxide
buildup. Replace the nozzle, turn on the power and
continue cutting. If the safety circuit continues to
trip after cleaning the consumables, then replace
them with a new set. Do not continue to try and
cut with excessively worn consumables as this can
cause damage to the torch head and will degrade
cut quality. Do not allow torch cable or body to
contact hot surface.
2. To improve consumable life, here are some sug-
gestions that may be useful:
• Make sure the air supply to the TOMAHAWK™
625 is clean and free of oil. Use several extra in
line filters if necessary.
• Minimize dross buildup on the nozzle tip by
starting the cut from the edge of the plate when
possible.
• Pierce cutting should be done only when nec-
essary. If piercing, angle torch about 30° from
the plane perpendicular to the work piece,
transfer the arc, then bring the torch perpendic-
ular to the work and begin parallel movement.
• Reduce the number of pilot arc starts without
transferring to the work.
• Reduce the pilot arc time before transferring to
the work.
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B-9
B-9
OPERATION
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TORCH PART CONFIGURATIONS
There are different torch configurations depending on
the cutting or gouging application.
Standard Cutting Setup:
In the Standard Cutting configuration the nozzle is
designed not to touch the work piece. The advantage
of this cutting method is good visibility of the arc.
However it requires a steady hand to avoid touching
the nozzle to the work piece which will cause prema-
ture nozzle wear and a jagged cut. An optional drag
spacer can be attached to the retaining cap to main-
tain a consistent arc height.
Contact Cutting Setup:
Contact Cutting uses special expendable parts that
allow the torch to touch the work piece. The advan-
tage of contact cutting is that the torch can touch the
work piece, steadily dragging it across the surface.
The disadvantage of contact cutting is the plasma arc
is not as visible as with a standard torch set-up. Since
this machine cuts at 40 amps or less it uses the direct
contact torch configuration which allows a special noz-
zle to come in contact with the work piece.
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B-10
ci .com
B-10
OPERATION
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Gouging Setup:
If gouging metal and not cutting completely through
the part is required, a special gouging nozzle is used
in conjunction with a gouge shield to protect the noz-
zle from molten metal blow back.
Refer to the torch parts decal located on your machine
or the parts pages at the back of this manual for the
specific part numbers required for each of these
setups.
ALWAYS USE GENUINE LINCOLN ELECTRIC
ELECTRODES, NOZZLES, AND EXPENDABLE
PARTS FOR THE BEST CUTTING PERFOR-
MANCE.
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C-1
C-1
ACCESSORIES
GENERAL OPTIONS /ACCESSORIES
The following options/accessories are available for
your Tomahawk Plasma cutter from your local Lincoln
Distributor.
K2377-1 - Small Canvas Cover
Protect your machine when not in use. Made from
attractive red canvas that is flame retardant, mildew
resistant and water repellent. It includes a convenient
side pocket to hold the plasma torch.
K2886-1 - Plasma Circle Cutting Kit
For cutting circles from 3” to 33” in diameter (77mm to
838mm).
TORCHES
The following replacement torch is available:
K2847-1 LC40 Handheld Plasma Torch 20' (6m)
EXPENDABLE PARTS
Refer to the torch parts decal located on your machine
or the parts pages at the back of this manual for the
specific part numbers required for each of the avail-
able setups.
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D-1
D-1
MAINTENANCE
PERIODICꢀMAINTENANCE
WARNING
WARNING
ELECTRIC SHOCK CAN KILL.
• Turn off machine at the disconnect
switch on the rear of the machine
before tightening, cleaning or
ELECTRICꢀSHOCK CAN KILL.
• Have an electrician install and ser-
vice this equipment.
• Turn the input power off at the fuse
box before working on equipment.
• Do not touch electrically hot parts.
replacing consumables.
----------------------------------------------------------------------------
Change consumables as required.
---------------------------------------------------------------------
ROUTINEꢀMAINTENANCE
THERMAL PROTECTION
1. Keep the cutting or gouging area and the area
around the machine clean and free of combustible
materials. No debris should be allowed to collect
which could obstruct air flow to the machine.
Thermal Detection Devices protect the machine from
excessive operating temperatures. Excessive temper-
atures may be caused by a lack of cooling air or oper-
ating the machine beyond the duty cycle and output
rating. If excessive operating temperatures should
occur, the yellow thermal LED will light and the
Detection Devices will prevent output voltage or cur-
rent.
2. Every 6 months or so, the machine should be
cleaned with a low pressure airstream. Keeping the
machine clean will result in cooler operation and
higher reliability. Be sure to clean these areas:
- Printed circuit boards and heat sinks
- Power switch
These Detection Devices are self-resetting once the
machine cools sufficiently. If the thermostat shutdown
was caused by excessive output or duty cycle and the
fan is operating normally, the Power Switch may be
left on and the reset should occur within a 15 minute
period. If the fan is not turning or the air intake louvers
were obstructed, then the power must be switched off
and the fan problem or air obstruction must be cor-
rected.
CAUTION
• When using a low pressure air stream, wear
appropriate eye protection.
------------------------------------------------------------------------
3. Examine the sheet metal case for dents or break-
age. Repair the case as required. Keep the case in
good condition to insure that high voltage parts are
protected and correct spacings are maintained. All
external sheet metal screws must be in place to
insure case strength and electrical ground continu-
ity.
A protection circuit is included to monitor the voltage
across filter capacitors. In the event that the capacitor
voltage is too high, the protection circuit will prevent
output.
4. Inspect the cable periodically for any slits or punc-
ture marks in the cable jacket. Replace if neces-
sary. Check to make sure that nothing is crushing
the cable and blocking the flow of air through the
air tube inside. Also, check for kinks in the cable
periodically and relieve any so as not to restrict the
flow of air to the torch.
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E-1
E-1
TROUBLESHOOTING
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and
machine operator and will invalidate your factory warranty. For your safety and to avoid
Electrical Shock, please observe all safety notes and precautions detailed throughout this
manual.
__________________________________________________________________________
This Troubleshooting Guide is provided to
help you locate and repair possible machine
malfunctions. Simply follow the three-step
procedure listed below.
Step 3. RECOMMENDED COURSE OF
ACTION
This column provides a course of action for
the Possible Cause, generally it states to
contact you local Lincoln Authorized Field
Service Facility.
Step 1. LOCATE PROBLEMꢀ(SYMPTOM).
Look under the column labeled “PROBLEM
(SYMPTOMS)”. This column describes
possible symptoms that the machine may
exhibit. Find the listing that best describes
the symptom that the machine is exhibiting.
If you do not understand or are unable to
perform the Recommended Course of
Action safely, contact you local Lincoln
Authorized Field Service Facility.
Step 2. POSSIBLE CAUSE.
The second column labeled “POSSIBLE
CAUSE” lists the obvious external possibili-
ties that may contribute to the machine
symptom.
WARNING
ELECTRIC SHOCK CAN KILL.
• Turn off machine at the disconnect
switch on the rear of the machine and
remove main power supply connec-
tions before doing any troubleshooting.
----------------------------------------------------------------------------
CAUTION
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.
TOMAHAWK™ 625
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E-2
E-2
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE
CAUSE
RECOMMENDED
COURSE OF ACTION
Input circuit breaker trips repeatedly. 1. This may be normal. If output is
set to maximum a 30 amp circuit
is required. See Technical
Specification page.
2. Install a larger input circuit or turn
the output control to a lower
amperage.
No Status indicators light and the fan 1. Check the input power to be sure
does not operate 5 seconds after the it is on.
power switch is turned on.
2. Check the power line fuses or
breakers and machine connection.
3. Disconnect input power at
fuse/breaker panel and check line
switch continuity. Replace line
switch if bad.
No Status indicators light 5 seconds 1. Possible faulty Inverter Board.
after the power switch is turned on,
If all recommended possible areas of
misadjustment have been checked
and the problem persists, Contact
your local Lincoln Authorized
Field Service Facility.
but the fan operates.
2. Possible faulty Control Board.
The Thermal LED does not go out. 1. Check consumables - Thermal
and output LED’s light when an
unsafe condition exists at the
torch.
2. Possible faulty Inverter Board.
3. Possible faulty Control Board.
CAUTION
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.
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E-3
E-3
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE
CAUSE
RECOMMENDED
COURSE OF ACTION
The TOMAHAWK™ 625 powers up 1. Turn the output knob to purge
properly but there is no response zone on the front of the TOMA-
when the trigger is pulled and only HAWK™ 625. If air does not flow,
the POWER LED is lit.
then:
• The main gas solenoid assem-
bly/pressure sensor may be
faulty. Check or replace.
• Possible faulty Control board.
2. Remove the handles (or barrel) of
the torch and examine all the con-
nections.
3. Check for proper trigger switch
operation. Replace the trigger
switch or torch cable if defective.
4. Possible faulty Inverter Board.
5. Possible faulty Control board.
If all recommended possible areas of
misadjustment have been checked
and the problem persists, Contact
your local Lincoln Authorized
Field Service Facility.
CAUTION
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.
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E-4
E-4
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE
CAUSE
RECOMMENDED
COURSE OF ACTION
When the trigger is pulled air begins 1. Check the torch consumables to be
to flow, but there is no pilot arc after
at least 3 seconds.
sure they are not dirty or greasy,
and are in good shape. Replace
the consumables if necessary.
2. Make sure the air pressure is set
correctly.
3. Make sure there are no kinks or
restrictions for air flow in the torch
cable. Replace cable as needed.
4. If a slight thump cannot be felt in
the torch when the trigger is
pulled, check for loose connection
in the torch head.
5. Possible faulty Inverter board.
The air begins to flow and there is a 1. Check the torch consumables to
very brief arc that snaps out consis- be sure they are in tight, not dirty
tently with repeated trigger pulls.
or greasy and in good shape.
Replace if necessary.
If all recommended possible areas of
misadjustment have been checked
and the problem persists, Contact
your local Lincoln Authorized
Field Service Facility.
2. Make sure the air pressure is set
correctly.
3. Possible faulty Inverter board.
The arc starts but sputters badly.
1. Check the torch consumables to
be sure they are in tight, not dirty
or greasy and in good shape.
Replace if necessary.
2. Check air supply for oil or a great
deal of water. If there is oil or a
great deal of water, the air must
be filtered or the machine
switched to nitrogen or bottled air.
3. Make sure the air pressure is set
correctly.
CAUTION
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.
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E-5
E-5
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE
CAUSE
RECOMMENDED
COURSE OF ACTION
Pilot arc starts but will not transfer 1. Check work lead connection for
when brought near work.
clean, secure connection.
2. Plasma will only cut conductive
material. Do not attempt to cut
fiberglass, plastic, rubber, PVC or
any other non-conductive material.
If all recommended possible areas of
misadjustment have been checked
and the problem persists, Contact
your local Lincoln Authorized
Field Service Facility.
3. Make sure work piece is clean
and dry. Remove any scale, rust
or dross.
4. Possible faulty Inverter board.
5. Check all connections to Control
Board.
Lower air pressure by turning regula-
tor knob. Pressure may require
being set lower than blue arrow indi-
cator.
Pilot arc initiates but turns off before 1. Input voltage is below 208V.
transferring to work. Cutting arc
appears to turn off while cutting.
2. Air pressure is set too high.
CAUTION
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.
TOMAHAWK™ 625
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E-6
E-6
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
STATUS BOARDꢀINDICATORS
SYMPTOM
CHECK
When trigger is pulled Red output LED is
Blinking or steady with no air flow.
1. Make sure there is at least 80 psi connected to the gas connec-
tion at the back of the machine.
2. Turn the output knob to the purge zone and set the regulator to
the correct pressure. The pressure may increase when air stops
flowing but this is normal. Do not reset the pressure while the air
is OFF.
3. Possible faulty Pressure Switch.
4. Possible faulty Inverter board.
The Green, Red and Yellow LED’s are lit
and steady. Indicates safety circuit is open.
1. Turn the power OFFꢀand then ON. If torch and consumables are
properly installed and they are the correct parts, the Red and
Yellow LED’s should turn off. Normal cutting or gouging can
resume.
The Thermal LED is lit.
1. The machine's thermostat has tripped due to exceeded duty
cycle limits. Do NOT turn the power off. Allow the machine to
cool for 15 - 30 minutes and the thermostat will reset itself.
2. The machine's air louvers or fans are obstructed such that air
cannot flow to properly cool the machine. Remove any foreign
material that may block air flow. Blow the machine out with a
clean, dry air stream.
3. The input voltage is not within ±10% of rated values.
4. Possible faulty Inverter board.
When the trigger is pulled the Red and
Yellow LED’s are blinking together and the
Green light is on.
1. Check that nozzle and swirl ring are properly installed and they
are the correct parts. Note: Swirl ring can only go in one way.
2. Input voltage is too low and /or air pressure is set too high.
Lower air pressure.
When the trigger is pulled the Red LED is lit, 1. Check that swirl ring is properly installed.
air flows and no pilot arc occurs.
Note: Swirl ring can only go in one way.
The Red and Yellow LED’s are blinking
alternately.
1. The torch safety circuit has been opened, when reconnected this
condition should correctly reset automatically.
When the trigger is pulled no air flows, Red 1. Check that the pressure gauge shows pressure.
LED is lit, no pilot arc. Then LED goes out.
Air supply may not be connected or properly installed.
TOMAHAWK™ 625
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F-1
S
F-1
ENHANCED DIAGRAM
DIAGRAMS
11
TOMAHAWK™ 625
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•
•
Do not touch electrically live parts or
electrode with skin or wet clothing.
Insulate yourself from work and
ground.
•
•
Keep flammable materials away.
•
•
Wear eye, ear and body protection.
WARNING
Spanish
•
No toque las partes o los electrodos
bajo carga con la piel o ropa moja-
da.
Mantenga el material combustible
fuera del área de trabajo.
Protéjase los ojos, los oídos y el
cuerpo.
AVISO DE
PRECAUCION
French
•
•
Aislese del trabajo y de la tierra.
Ne laissez ni la peau ni des vête-
ments mouillés entrer en contact
avec des pièces sous tension.
Isolez-vous du travail et de la terre.
•
•
Gardez à l’écart de tout matériel
inflammable.
•
•
Protégez vos yeux, vos oreilles et
votre corps.
ATTENTION
•
•
German
Berühren Sie keine stromführenden
Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!
Isolieren Sie sich von den
Entfernen Sie brennbarres Material!
Tragen Sie Augen-, Ohren- und Kör-
perschutz!
WARNUNG
•
Elektroden und dem Erdboden!
Portuguese
•
•
Não toque partes elétricas e electro-
dos com a pele ou roupa molhada.
Isole-se da peça e terra.
•
Mantenha inflamáveis bem guarda-
dos.
•
Use proteção para a vista, ouvido e
corpo.
ATENÇÃO
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE
CONSUMABLES TO BE USED AND FOLLOWYOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEERY ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE
ESTE EQUIPOY LOS CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU
SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT
ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE
EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRO-
DENEINSATZ DES HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS
SIND EBENFALLS ZU BEACHTEN.
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•
•
Keep your head out of fumes.
Use ventilation or exhaust to
remove fumes from breathing zone.
•
•
Turn power off before servicing.
•
•
Do not operate with panel open or
guards off.
WARNING
Spanish
•
•
Los humos fuera de la zona de res-
piración.
Mantenga la cabeza fuera de los
humos. Utilice ventilación o
aspiración para gases.
Desconectar el cable de ali-
mentación de poder de la máquina
antes de iniciar cualquier servicio.
No operar con panel abierto o
guardas quitadas.
AVISO DE
PRECAUCION
French
•
•
Débranchez le courant avant l’entre-
tien.
•
•
N’opérez pas avec les panneaux
ouverts ou avec les dispositifs de
protection enlevés.
•
•
Gardez la tête à l’écart des fumées.
Utilisez un ventilateur ou un aspira-
teur pour ôter les fumées des zones
de travail.
ATTENTION
German
Strom vor Wartungsarbeiten
abschalten! (Netzstrom völlig öffnen;
Maschine anhalten!)
Anlage nie ohne Schutzgehäuse
oder Innenschutzverkleidung in
Betrieb setzen!
•
•
Vermeiden Sie das Einatmen von
Schweibrauch!
Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
WARNUNG
Portuguese
•
•
Não opere com as tampas removidas.
Desligue a corrente antes de fazer
serviço.
•
•
Mantenha-se afastado das partes
moventes.
Não opere com os paineis abertos
ou guardas removidas.
•
•
Mantenha seu rosto da fumaça.
Use ventilação e exhaustão para
remover fumo da zona respiratória.
ATENÇÃO
•
Não toque as partes elétricas nuas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES
DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
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• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEBꢀSITE: www.lincolnelectric.com
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