Lincoln Electric Welding System IM595 A User Manual
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IM595-A  
TM  
May, 2004  
PRO-CUT 80  
For use with machines having Code Numbers:  
10573, 10574, 10575, 10576, 10577, 10578  
11019, 11020, 11021, 11022, 11023, 11024  
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 thought-  
ful operation on your part. DO  
NOT INSTALL, OPERATE OR  
REPAIR THIS EQUIPMENT  
WITHOUT READING THIS  
MANUAL AND THE SAFETY  
PRECAUTIONS CONTAINED  
THROUGHOUT. And, most  
importantly, think before you act  
and be careful.  
OPERATOR’S MANUAL  
Copyright © 2004 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 WEB SITE: www.lincolnelectric.com  
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ii  
SAFETY  
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.  
PLASMA ARC can injure.  
7.a. Keep your body away from nozzle and  
plasma arc.  
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.  
7.b. Operate the pilot arc with caution. The pilot arc is capable of  
burning the operator, others or even piercing safety clothing.  
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.  
ELECTRIC AND MAGNETIC FIELDS  
may be dangerous  
5.b. Always keep cylinders in an upright position securely  
chained to an undercarriage or fixed support.  
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.  
5.c. Cylinders should be located:  
• Away from areas where they may be struck or subjected to  
physical damage.  
• A safe distance from plasma cutting or gouging, arc weld-  
ing operations and any other source of heat, sparks,  
or flame.  
8.b. EMF fields may interfere with some pacemakers, so opera-  
tors having a pacemaker should consult their physician  
before cutting or gouging.  
5.d. Never allow any part of the electrode, torch or any other  
electrically “hot” parts to touch a cylinder.  
8.c. Exposure to EMF fields during cutting or gouging may have  
other health effects which are now not known.  
5.e. Keep your head and face away from the cylinder valve outlet  
when opening the cylinder valve.  
8d. All operators should use the following procedures in order to  
minimize exposure to EMF fields from the cutting or gouging  
circuit:  
5.f. Valve protection caps should always be in place and hand  
tight except when the cylinder is in use or connected for  
use.  
8.d.1. Route the torch and work cables together - Secure  
them with tape when possible.  
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.  
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.  
FOR ELECTRICALLY  
powered equipment.  
8.d.4. Connect the work cable to the workpiece as close as  
possible to the area being cut or gouged.  
6.a. Turn off input power using the disconnect  
switch at the fuse box before working on the  
equipment.  
8.d.5. Do not work next to cutting power source.  
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.  
Apr. ‘93  
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NOTES  
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SAFETY  
zones où l’on pique le laitier.  
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  
1. Protegez-vous contre la secousse électrique:  
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.  
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.  
b. Porter des vêtements convenables afin de protéger la  
peau de soudeur et des aides contre le rayonnement de  
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.  
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  
Mar. ‘93  
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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  
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 WEB SITE 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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vi  
TABLE OF CONTENTS  
Page  
Installation.......................................................................................................................Section A  
Technical Specifications.......................................................................................................A-1  
Safety Precautions ...............................................................................................................A-2  
Select Proper Location.........................................................................................................A-2  
Stacking................................................................................................................................A-2  
Lifting and Moving ................................................................................................................A-2  
Tilting....................................................................................................................................A-2  
High Frequency Interference Protection...............................................................................A-2  
Input Electrical Connections.................................................................................................A-3  
Power Input Connection for 208/230/460 Volt Machines .....................................................A-3  
Power Input Connection for 200/380-415 Volt Machines.....................................................A-3  
Input Power Cord Connector Installation..............................................................................A-3  
Cord Removal ...............................................................................................................A-3  
Cord Installation ............................................................................................................A-3  
Frame Grounding .................................................................................................................A-4  
Input Voltage Reconnection Procedure................................................................................A-4  
Use on Engine Driven Power Supplies ................................................................................A-4  
Gas Input Connections.........................................................................................................A-5  
Output Connections..............................................................................................................A-5  
Torch Connection..........................................................................................................A-5  
Operation.........................................................................................................................Section B  
Safety Precautions ...............................................................................................................B-1  
Description ...........................................................................................................................B-1  
Preheat Temperature for Plasma Cutting.............................................................................B-1  
User Responsibility...............................................................................................................B-2  
Recommended Processes and Equipment..........................................................................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  
Gas Pressure Settings .........................................................................................................B-4  
Preparing to Cut ...................................................................................................................B-4  
Safety LED ...........................................................................................................................B-5  
Pilot Arc Discussion..............................................................................................................B-6  
Procedure Recommendations..............................................................................................B-6  
General .........................................................................................................................B-6  
Thin Gauge Sheet Metal ...............................................................................................B-6  
Thick Sections of Metal.................................................................................................B-6  
Suggestions for Extra Utility from the PRO-CUT System .............................................B-7  
Machine Interface.................................................................................................................B-7  
Accessories.....................................................................................................Section C  
Genuine Lincoln Parts ...........................................................................................C-1  
General Options / Accessories..............................................................................C-1  
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vii  
TABLE OF CONTENTS  
Page  
Maintenance ....................................................................................................Section D  
Safety Precautions ................................................................................................D-1  
Input Filter Capacitor Discharge Procedure ..........................................................D-1  
Routine Maintenance.............................................................................................D-2  
Periodic Maintenance............................................................................................D-2  
Troubleshooting..............................................................................................Section E  
Safety Precautions.................................................................................................E-1  
How to Use Troubleshooting Guide.......................................................................E-1  
Troubleshooting Guide.............................................................................E-2 thru E-7  
Wiring Diagrams..............................................................................................Section F  
Wiring Diagrams.......................................................................................F-1 thru F-4  
Dimension Print......................................................................................................F-5  
Parts List........................................................................................P340, P210-K Series  
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A-1  
A-1  
INSTALLATION  
TECHNICAL SPECIFICATIONS - PRO-CUT 80  
INPUT  
THREE PHASE  
SINGLE PHASE  
Input Current  
at Rated Output  
87/81/48  
Standard  
Voltage  
208/230/460  
200/380-415  
460/575  
Input Current  
at Rated Output  
48/44/25  
Standard  
Voltage  
208/230/460  
Model  
Model  
50/60Hz  
50/60 Hz  
50/60 Hz  
50/60 Hz  
46/27/24  
25/20  
RATED OUTPUT  
Duty Cycle  
AMPS  
VOLTS  
60% Duty Cycle  
100% Duty Cycle  
80  
60  
140  
130  
OUTPUT  
Current  
Range  
Open Circuit  
Pilot Current  
Voltage  
MAX  
20 Amps @ 100% Duty Cycle  
335 VDC  
35-85 Amps  
REQUIRED GAS FLOW RATE  
REQUIRED GAS INLET PRESSURE  
70 PSI @ 480 SCFH  
80 to 120 PSI  
( 4.8 Bar. @ 13550 LHR)  
( 5.4 Bar. to 8.1 Bar.)  
RECOMMEND INPUT WIRE AND FUSE SIZES  
For all plasma cutting applications Based on U.S. National Electrical Code  
o
Ambient Temperature 30 C or Less  
RECOMMENDED INPUT WIRE AND FUSE SIZES  
THREE PHASE  
SINGLE PHASE  
Type 75°C  
Copper  
Ground  
Wire in  
Conduit  
AWG (IEC)  
Sizes  
Type 75°C  
Copper  
Ground  
Wire in  
Conduit  
AWG (IEC)  
Sizes  
Type 75°C  
Copper  
Wire in  
Conduit  
AWG (IEC)  
Sizes  
Type 75°C  
Copper  
Wire in  
Conduit  
AWG (IEC)  
Sizes  
Fuse  
(Superlag)  
or  
Fuse  
(Superlag)  
or  
Input  
Voltage  
Frequency  
Input  
Voltage  
Frequency  
Breaker  
Size  
Breaker  
Size  
(1)  
(1)  
2
2
2
2
200/50/60  
208/50/60  
60  
60  
8 (8.4mm )  
8 (8.4mm )  
208/50/60  
230/50/60  
460/50/60  
100  
100  
60  
4 (21.1mm ) 4 (21.1mm )  
2
2
2
2
8 (8.4mm )  
8 (8.4mm )  
4 (21.1mm ) 4 (21.1mm )  
2
2
2
2
230/50/60  
60  
40  
40  
30  
8 (8.4mm )  
8 (8.4mm )  
8 (8.4mm )  
8 (8.4mm )  
2
2
380-415/50/60  
460/50/60  
10 (6mm )  
10 (6mm )  
2
2
10 (6mm )  
10 (6mm )  
2
2
575/50/60  
10 (6mm )  
10 (6mm )  
PHYSICAL DIMENSIONS  
Weight  
Height  
Width  
Depth  
Including Machine, Torch and  
Torch Cable (Length)  
(25ft/7.6m) (50ft/15.2m)  
16.5 in.  
419 mm  
13.75 in.  
349 mm  
29.5 in.  
749 mm  
98 lbs.  
113 lbs.  
51.4 kg.  
44.5 kg.  
(1) Input voltage must be within 10% of rated value.  
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A-2  
A-2  
INSTALLATION  
Read entire Installation Section before installing the  
PRO-CUT 80.  
LIFTING AND MOVING  
Either the front or rear handles or both may be used to  
lift or move the machine.  
SAFETY PRECAUTIONS  
WARNING  
DO NOT use the pull handle on the optional undercar-  
riage, if installed, to lift the machine. This handle is not  
designed to support the full weight of the machine and  
using it to lift the machine could cause personal injury  
or damage to the machine.  
ELECTRIC SHOCK CAN KILL.  
•
Only qualified personnel  
should install this machine.  
TILTING  
•
Turn the input power OFF  
at the disconnect switch or  
fuse box and discharge input  
capacitors before working  
inside the equipment.  
The PRO-CUT 80 must be placed on a stable, level  
surface so it will not topple over.  
HIGH FREQUENCY INTERFERENCE  
PROTECTION  
•
•
Do not touch electrically hot parts.  
The PRO-CUT 80 employs a touch start mechanism  
for arc initiation which eliminates high frequency emis-  
sions from the machine as compared with spark gap  
and solid state type high frequency generators. Keep  
in mind, though, that these machines may be used in  
an environment where other high frequency generat-  
ing machines are operating. By taking the following  
steps, high frequency interference into the Pro-Cut  
can be minimized  
Always connect the PRO-CUT 80 ground-  
ing terminal (located on the side of the  
Case Back Assembly) to a good electrical  
earth ground.  
•
Turn the PRO-CUT Power Switch OFF  
when connecting power cord to input  
power.  
___________________________________________  
(1) Make sure the power supply chassis is connected  
to a good earth ground. The work terminal ground  
does NOT ground the machine frame.  
SELECT PROPER LOCATION  
Place the PRO-CUT 80 where clean cool air can  
freely circulate in through the rear louvers and out  
through the side/bottom openings. 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 temper-  
atures and nuisance shutdown of the machine.  
(2) Keep the work ground clamp isolated from other  
work clamps that have high frequency.  
(3) If the ground clamp cannot be isolated, then keep  
the clamp as far as possible from other work  
clamp connections.  
A source of clean, dry air or nitrogen must be supplied  
to the PRO-CUT 80. Oil in the air is a severe problem  
and must be avoided. The supply pressure must be  
between 80 and 120 psi. The flow rate is approximate-  
ly 8.0 cfm (227 l/min.). Failure to observe these pre-  
cautions could result in excessive operating tempera-  
tures or damage to the torch.  
(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.  
Failure to observe these recommended installation  
procedures may cause improper function of the Pro-  
Cut or possibly even damage to the control system or  
power supply components.  
STACKING  
The PRO-CUT 80 cannot be stacked.  
PRO-CUT 80  
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A-3  
A-3  
INSTALLATION  
CORD REMOVAL:  
INPUT ELECTRICAL  
CONNECTIONS  
1. Unplug line cord from the receptacle.  
WARNING  
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.  
NOTE: DO NOT PERFORM THE NEXT STEP  
UNTIL THE HIGH VOLTAGES INSIDE THE  
MACHINE HAVE BEEN ALLOWED TO DISSIPATE,  
APPROXIMATELY TWO MINUTES.  
The Pro-Cut 80 should be connected only by a quali-  
fied electrician. Installation should be made in accor-  
dance with all local and national codes (eg: U.S.  
National Electrical Code) and the information detailed  
below.  
------------------------------------------------------------------------  
2. Remove wraparound by unscrewing the eleven  
screws on the case sides and top.  
3. Unscrew the four screws that hold the line switch  
onto the case front.  
4. Pull the line switch out of the case front.  
5. Angle the line switch so the nuts on the switch can  
be loosened.  
THREE PHASE POWER INPUT CONNEC-  
TION FOR THE PRO-CUT 80  
6. Remove the cord from the switch.  
7. Remove the nut, lock washer, plain washer and  
green lead off of the ground screw assembly.  
8. Loosen the cable connector on the case back.  
9. Pull the line cord out of the machine.  
The Pro-Cut 80’s are supplied with one 10 ft. #8 AWG  
4-conductor input power cord already connected to  
the machine. When received from the factory, the  
machine is internally connected for the higher input  
voltage. Re-connection will be necessary if a lower  
input voltage is used.  
CORD INSTALLATION:  
CONVERTING THE PRO-CUT 80 FROM  
THREE PHASE TO SINGLE PHASE INPUT  
1. Feed the new cord through the cable connector  
and into the machine.  
2. If the ground screw assembly is loose, tighten the  
assembly to the base before installing the new  
ground lead. Install the green lead on the ground  
screw assembly, replace the plain washer and lock  
washer, then tighten nut. Install in accordance with  
all local and national electrical codes.  
3. Connect the new cord to the switch, observing the  
color code on the wiring diagram.  
4. Feed the line switch back into case front.  
5. Replace the four screws that hold the line switch  
onto the case front.  
To convert to single phase power, the 4-conductor  
input cord may still be used, but the red lead must be  
disconnected and insulated.  
1. Connect the green lead to ground per U.S. National  
Electrical Code.  
2. Connect black and white leads to power.  
3. Wrap red lead with tape to provide 600V insulation.  
6. Tighten the cable connector on the case back.  
7. Replace wraparound and tighten the eleven  
screws on the case sides and top.  
8. Connect the new input power cord to a fused three  
phase power supply. Make sure the green lead is  
connected to the panel and the panel is connected  
to a good earth ground. Install in accordance with  
all local and national electric codes.  
WARNING  
Machine damage could result if the machine is  
improperly configured for the Input Voltage  
applied.  
------------------------------------------------------------------------  
INPUT POWER CORD CONNECTOR  
INSTALLATION  
NOTE: Fusing requirements of the machine input will  
change, depending on whether the machine is used  
on single phase or three phase. Use the chart in the  
TECHNICAL SPECIFICATIONS to change the fuses  
to the proper value.  
A cord connector provides a strain relief for the input  
power cord as it passes through the left rear access  
hole. The cord connector is designed for a cord diam-  
eter of .40 - 1.03 in (10.2 - 26.2mm) if it becomes nec-  
essary to install a different input cord.  
PRO-CUT 80  
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A-4  
A-4  
INSTALLATION  
For 380 - 415 VAC Supplies:  
FRAME GROUNDING  
The AC wave form peak voltage must be below 840  
volts.  
The RMS voltage must be 400 VAC +/- 10%.  
The frame of the Pro-Cut 80 must be properly ground-  
ed. A ground terminal marked  
is mounted on the  
case bottom directly behind the input power switch for  
this purpose. The cable that is sent attached to the  
machine is connected to this ground terminal. See the  
National Electric Code for details on proper grounding  
methods. Install in accordance with all local and  
national electrical codes.  
For 460 VAC Supplies:  
The AC wave form peak voltage must be below 840  
volts.  
The RMS voltage of the AC wave form must be 460  
VAC +/- 10%.  
INPUT VOLTAGE RECONNECTION  
PROCEDURE  
Input Power Restrictions  
The available output current of the Pro-Cut 80 may be  
limited due to the output capacity of the engine driven  
power supply. The following are recommended output  
current settings when used with various Lincoln  
engine driven power supplies.  
When changing input voltages, it is necessary to  
change the settings behind the access door on the  
side of the machine. Failure to do so may result in  
damage to the machine.  
To reconnect the Pro-Cut, follow the directions as out-  
lined below. Follow this procedure ONLY while the  
Pro-Cut is disconnected from the input power and the  
capacitors have properly discharged.  
Engine Drive  
Auxiliary Power Pro-Cut 80 Output Cut Thickness  
RANGER 8  
RANGER 9  
GX271  
8KW  
9KW  
30 Amps  
40 Amps  
30 Amps  
40 Amps  
35 Amps  
55 Amps  
40 Amps  
40 Amps  
45 Amps  
45 Amps  
55 Amps  
55 Amps  
5/16”  
3/8”  
5/16”  
3/8”  
5/16”  
5/8”  
3/8”  
3/8”  
1/2”  
1/2”  
5/8”  
5/8”  
8KW  
9KW  
1. Open the access door on the back of the machine.  
RANGER 275  
RANGER 250  
RANGER 300D  
RANGER 305G  
RANGER 305D  
COMMANDER 300  
COMMANDER 400  
COMMANDER 500  
VANTAGE 500  
8.5KW  
12KW  
9.5KW  
9.5KW  
10KW  
10K  
2. For 200 to 230 : Position the large switch to 200-230.  
For 400 to 460 : Position the large switch to 400-460.  
For 550 to 575 : Position the large switch to 550-575.  
12KW  
12KW  
3. Move the "A" lead to the appropriate terminal.  
USE ON ENGINE DRIVEN POWER SUPPLIES  
The Pro-Cut 80 can be used on engine driven power  
supplies. However, the following AC Wave Form  
Voltage and Input Power Restrictions do apply.  
AC Wave Form Restrictions  
The Pro-Cut 80 can be operated on engine driven  
generators as long as the engine drive output meets  
the following conditions:  
The AC wave form frequency is between 45 and 65  
Hz.  
For 200 - 230 VAC Supplies:  
The AC wave form peak voltage must be below 420  
volts.  
The RMS voltage must be 230VAC +/- 15%.  
* The 230 VAC auxiliaries of Lincoln engine drives  
meet these conditions when run in the high idle  
mode.  
PRO-CUT 80  
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A-5  
A-5  
INSTALLATION  
• While it is recommended that an in line prefilter be  
placed ahead of each PRO-CUT that may be  
installed in a shared air supply line, one large inline  
prefilter may instead be used to accommodate sev-  
eral PRO-CUTs simultaneously. If a shared prefilter  
is desired, it must be rated to provide the necessary  
flow rate, as specified, to ensure proper operation of  
each of the PRO-CUTs sharing a connection.  
GAS INPUT CONNECTIONS  
Supply the PRO-CUT 80 with clean compressed air or  
nitrogen.  
2
• Supply pressure must be between 80 psi(5.6kg/cm )  
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 ) for  
a 25ft.(7.6m) torch and 75 psi(5.3kg/cm ) for a 50  
ft.(15.2m) torch while gas is flowing (purging or cut-  
ting).  
2
NOTE: When using nitrogen gas from a cylinder, the  
2
cylinder must have a pressure regulator.  
• Maximum psi from nitrogen gas cylinder to PRO-  
CUT 80 regulator should never exceed 120  
• Flow rate should be approximately 8.0 cfm (227  
I/min.).  
2
psi(8.4kg/cm ).  
NOTE: Oil in the air supply to the PRO-CUT 80 can  
• Install a hose between the nitrogen gas cylinder reg-  
ulator and the PRO-CUT 80 gas inlet.  
cause severe problems. Use only a clean air  
supply.  
• Connect the gas supply to the PRO-CUT 80 regula-  
tor.  
WARNING  
• Compressed gas should be supplied to the fitting  
connection mounted on the filter at the rear of the  
machine. If necessary, this fitting can be removed  
allowing plumbing access through the 1/4” NPT input  
port on the filter body.  
• CYLINDER could explode if  
damaged.  
• Keep cylinder upright and  
chained to a fixed support.  
• Keep cylinder away from areas  
where it could be damaged.  
• Never lift machine with cylinder  
attached.  
• If compressed air is being used, it is highly recom-  
mended that an inline prefilter be installed in the air  
supply line ahead of the air connection to the PRO-  
CUT’s coalescing filter. While the coalescing filter is  
used to remove small amounts of oil and water  
aerosol particles from the air supply line, the prefilter  
can be used to remove larger particulates before  
they reach the coalescing filter element. This will  
prolong the life of the coalescing filter element by up  
to six times what it would be without the prefilter, and  
in turn, prolong the life of the PRO-CUT torch and  
consumables as well.  
• Never allow the cutting torch to touch the cylin-  
der.  
• Keep cylinder away from live electrical parts.  
2
• Maximum inlet pressure 120 psi(8.4kg/cm ).  
__________________  
• A standard nominal 5 micron inline prefilter is recom-  
mended; however, for optimum performance, select  
a prefilter with a 3 micron absolute rating. If these fil-  
ter ratings are unavailable, anything with a rating  
less than, or equal to, 20 micron would be accept-  
able to use. In line filter elements will generally filter  
the air with little restriction to the airflow until the ele-  
ment 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  
OUTPUT CONNECTIONS  
Torch Connection  
The Pro-Cut 80 is sent from the factory with a PCT 80  
cutting torch. Additional cutting torches can be  
ordered from the K1571 series. Hand-held and mech-  
anized torches come with 25'(7.6m) or 50’(15.2m)  
cables.  
All torches are connected to the Pro-Cut with a quick  
connect on the case front for easy change over. This  
feature is excellent for changing between a hand cut-  
ting torch and a mechanized torch.  
2
drop of 8-10psi(.56-.70kg/cm ) is indicated; however,  
for optimum performance of the PRO-CUT, the filter  
element should be replaced at or before the pres-  
2
sure drop reaches 8 psi(.56kg/cm ). Be sure to  
For more information on the torch and its components,  
refer to the PCT80 Operator’s Manual (IM588 latest  
version).  
select a prefilter that will accommodate the neces-  
sary flow rating for the PRO-CUT as specified in the  
Installation section of this instruction manual under  
the Gas Input Connections heading.  
PRO-CUT 80  
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B-1  
B-1  
OPERATION  
Read and understand this entire section before oper-  
ating the machine.  
DESCRIPTION  
The PRO-CUT 80 is a constant current, continuous con-  
trol plasma cutting power source. It provides superior  
and reliable starting characteristics, cutting visibility and  
arc stability. When cutting expanded metal, the PRO-  
CUT 80 out performs the competition due to its quick,  
clean response to arc transfers. The power supply  
design provides high transfer-to-cut distances which  
makes pierce cutting more reliable and with less nozzle  
wear. The control system has a safety mechanism to  
insure that the nozzle and electrode are in place before  
cutting or gouging. This is extremely important due to the  
high voltages involved.  
SAFETY PRECAUTIONS  
WARNING  
ELECTRIC SHOCK  
can kill.  
• Do not touch electrically live parts  
or electrode with skin or wet  
clothing.  
• Insulate yourself from work and  
ground.  
The PRO-CUT 80 comes standard with an air regulator,  
coarse air filter, and pressure gauge. There are six differ-  
ent torch and cable systems to choose from: hand-held  
torch with 25'(7.6m) or 50'(15.2) cable, machine and  
robotic torch both with 25'(7.6m) and 50'(15.2) cable.  
Consumables are included so that cutting can begin right  
out of the box. Consumables can also be ordered as indi-  
vidual packages.  
• Always wear dry insulating  
gloves.  
FUMES AND GASES  
can be dangerous.  
• Keep your head out of fumes.  
The PRO-CUT 80 initiates the plasma arc with a simple,  
yet reliable, touch start mechanism. This system elimi-  
nates many of the failure problems associated with hi-fre-  
quency start systems. The PRO-CUT 80 is capable of  
cutting with nitrogen or air.  
• Use ventilation or exhaust to  
remove fumes from breathing  
zone.  
WELDING, CUTTING and  
GOUGING SPARKS  
The PRO-CUT 80 is controlled by a microprocessor-  
based control board. The machine performs rudimentary  
self troubleshooting when powered up which aids in field  
servicing.  
NOTE: All P.C. boards are protected by a moisture resis-  
tant coating. When the plasma cutter is operated, this  
coating will "bake off" of certain power resistors that nor-  
mally operate at high temperatures emitting some smoke  
and odor for a short time. These resistors and the P.C.  
board beneath them may become darkened. This is a  
normal occurrence and does not damage the component  
or affect the machine performance.  
can cause fire or explosion  
• 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.  
PREHEAT TEMPERATURE FOR  
PLASMA CUTTING  
PLASMA ARC  
can injure  
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 resis-  
tance and hardness control. Job conditions, prevailing  
codes, alloy level, and other considerations may also  
require preheat temperature control. The following mini-  
mum 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 mini-  
mum preheat temperature for plate thickness up to 1/2"  
(12.7mm) is 70°F (21.1°C).  
• 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.  
PRO-CUT 80  
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B-2  
B-2  
OPERATION  
- Input over voltage protection.  
USER RESPONSIBILITY  
- Bright 3.0 second timed pilot arc.  
- Purge momentary push button.  
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.  
- Air regulator and pressure gage located on the front  
of machine for convenience.  
- Parts-in-Place mechanism to detect proper installa-  
tion of consumables and torch.  
- Latching Parts-in-Place mechanism. Requires a  
positive operator reset.  
RECOMMENDED PROCESSES AND  
EQUIPMENT  
- Automatic detection of faulty output control.  
- In line coarse air filter.  
The PRO-CUT 80 is capable of all cutting and goug-  
ing applications within its output capacity of 35 to 85  
amps. These applications include thin gage sheet  
metal and expanded metal.  
- Preflow/Postflow timing. Preflow is eliminated if arc  
is re-initiated in Postflow.  
- Thermostatic Protection.  
OPERATIONAL FEATURES AND  
CONTROLS  
- Solid state over-current protection.  
- Works with pure nitrogen for cutting nonferrous  
materials.  
The PRO-CUT 80 comes with an ON/OFF POWER  
SWITCH, OUTPUT CURRENT CONTROL, PURGE  
BUTTON and a SAFETY RESET BUTTON.  
- Reconnectable for multiple input voltages.  
- Quick disconnect torch.  
DESIGN FEATURES AND  
ADVANTAGES  
- Dead front display for machine status.  
The microprocessor controlled PRO-CUT 80 design  
makes plasma cutting and gouging tasks uncomplicat-  
ed. This list of design features and advantages will  
help you understand the machine's total capabilities  
so that you can get maximum use from your machine.  
- Unique electrode and Vortech™ nozzle design for  
optimum cooling and long life.  
- Swirl texture inside Vortech™ nozzle for better start-  
ing reliability and higher quality cuts.  
- Unique drag cup design for durability and elimina-  
tion of double arcing.  
- Portable design for industrial use.  
- Continuous output control, 35 - 85 amps.  
- Reliable touch start mechanism for plasma arc initi-  
ation.  
- Unique microprocessor controlled starting sequence  
for safe and consistent starting.  
- Rapid arc transfer for fast cutting of expanded  
metal.  
- High transfer distance for ease of use.  
- Soft start of input filter capacitors at start up.  
PRO-CUT 80  
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B-3  
B-3  
OPERATION  
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, then  
idling for 4 minutes) or 60 amps, at 100% duty cycle (continuous use). 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 PRO-CUT 80 when cutting mild steel. The graph plots cut thickness vs.  
torch travel speed with a torch standoff of 0.15"(3.8mm). Example: 0.5”(12.7mm) material may be cut at a setting  
of 55 amps at an approximate speed of 25”/m(635mm/m) or at a setting of 80 amps at an approximate speed of  
35”/m(889mm/m).  
Lincoln’s PRO-CUT 80  
Mild Steel Cut Capacity Chart  
100  
2540  
80  
2032  
60  
1524  
40  
1016  
20  
508  
25 A  
55 A  
80 A  
35 A  
0
0.000  
0.125  
0.250  
0.375  
(9.5mm)  
0.500  
(12.7mm)  
0.625  
0.750  
1.00  
(25.4mm)  
(15.9mm) (19.1mm)  
(3.2mm) (6.4mm)  
Figure B.1  
CONSUMABLE LIFE  
The expected life for the PRO-CUT 80’s electrode under normal conditions is approximately 30 to 40 minutes of  
cutting time at the machine’s maximum rated output. An erosion of approximately 1/16" in the electrode tip is typ-  
ical for the end of electrode life, however, the electrode may last longer. A sustained green and erratic arc will  
indicate definite electrode failure and both the electrode and nozzle should be replaced immediately.  
It is recommended that consumables (electrode and nozzle) be replaced in complete sets. This will maximize the  
performance of the PRO-CUT system.  
PRO-CUT 80  
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B-4  
B-4  
OPERATION  
• Set the output current control knob at maximum  
position for high cutting speed and less dross forma-  
tion. Reduce the current, if desired to reduce the  
kerf (cut) width, heat affected zone or travel speed  
as required.  
LIMITATIONS  
Do not exceed the output current and duty cycle rating  
of machine. Do not use the PRO-CUT 80 for pipe  
thawing.  
GAS PRESSURE SETTINGS  
CONTROLS AND SETTINGS  
• Push-in and hold the Purge button to check or set  
the gas pressure. Pull the pressure regulator cap  
out and turn it to set the pressure.  
Gas  
Reset  
Button  
Purge  
Button  
2
Gas  
Regulator  
Gauge  
- Adjust the gas regulator for 70psi(4.9kg/cm ) for  
25’(7.6m) torches or 75psi(5.3kg/cm ) for  
50’(15.2m torches.  
Status  
Indicators  
2
- Release the Purge button.  
XXXX XXXX XXXX XXXX  
- 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.  
Gas  
Regulator  
Knob  
Output  
Control  
Knob  
PRO-CUT 80  
Consumable  
Storage  
(behind  
door)  
PREPARE TO CUT  
• When ready to cut, place the torch near the work,  
make certain all safety precautions have been taken  
and pull the trigger.  
Input  
- The air will flow for a preflow time of 2 seconds  
and the pilot arc will start. (This is true unless  
the machine is in postflow, then the preflow time  
is skipped and the pilot arc will start immediate-  
ly.)  
Power  
Switch  
Torch  
Connector  
Work  
Cable  
Interface  
Connector  
- 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 to improve parts life.  
- When the arc is brought within 1/4"(6.4mm) from  
the work piece: the arc will transfer, the current  
will ramp up to the setting on the control panel,  
and the cut can last indefinitely (or until the duty  
cycle of the Pro-Cut is exceeded). Do not touch  
the nozzle to the work when cutting with the  
control panel setting above 45 Amps or damage  
to the consumables will result.  
When preparing to cut or gouge, position the machine  
as close to the work as possible. Make sure you have  
all materials needed to complete the job and have  
taken all safety precautions. It is important to follow  
these operating steps each time you use the machine.  
• Turn the machine's ON/OFF POWER SWITCH to  
OFF position.  
• Connect the air supply to the machine.  
• Turn the main power and the machine power switch  
on.  
• 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.  
- The fan should start.  
- The pre-charge circuit will operate with all the  
LED’s lit and steady for 4 seconds, then all the  
LED’s should turn off except for the green  
"POWER" LED.  
- If the "SAFETY" LED is lit and steady, push the  
"RESET" button. If there is no problem, the LED  
will go off. If there is a problem, refer to the head-  
ing "SAFETY LED" in this section.  
TORCH AT 300 ANGLE  
TO PIERCE  
ROTATE TO  
900 ANGLE TO CUT  
300  
- If any of the other LED’s remain lit and steady,  
refer to the troubleshooting section of the manual.  
Gloves required  
900  
VERTICAL ANGLE  
FOR CUTTING  
• Be sure that the work lead is clamped to the work-  
piece before cutting.  
CUT  
PRO-CUT 80  
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B-5  
B-5  
OPERATION  
ANGLE  
OF APPROACH  
• Hold the nozzle standoff 1/8” (3.2mm) to 3/16”  
(4.8mm) above the workpiece during cutting. Do not  
let the nozzle touch the work or carry a long arc.  
Gloves Required  
TORCH HELD AT  
450 ANGLE  
THROUGHOUT GOUGE  
• Keep moving while cutting. Cut at a steady speed  
without pausing. Maintain the cutting speed so that  
the arc leg is 10° to 20° behind the travel direction.  
ANGLE  
MAINTAINED  
THROUGHOUT  
GOUGE  
5° - 15° Leading Angle  
SAFETY LED  
• If the "SAFETY" LED lights at any time, check the  
following:  
WARNING  
Direction of Travel  
ELECTRIC SHOCK CAN KILL.  
• Turn off machine at the disconnect  
switch on the front of the machine  
before tightening, cleaning or replacing  
consumables.  
10° - 20°  
Arc Lag  
----------------------------------------------------------------------------  
• Use a 5° - 15° leading angle in the direction of the  
cut.  
• In normal operation, the "SAFETY" LED may tem-  
porarily illuminate and clear itself automatically with-  
out depressing the reset button.  
• Use the drag cup to maintain constant standoff for  
better cut quality and to protect the nozzle from spat-  
ter.  
• 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.  
• Use the drag cup with a metal template to prevent  
nozzle double arcing.  
• 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 PRO-CUT system".  
• Finish the cut and release the trigger.  
• When the trigger is released, the arc will stop.  
- The gas will continue to flow for 10 seconds of  
postflow. If the trigger is activated within this time  
period, the pilot arc will immediately restart.  
• 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 1/16”. A green and erratic arc will  
indicate definite electrode failure and the electrode  
should be replaced immediately.  
• If the dross is difficult to remove, reduce the cutting  
speed. High speed dross is more difficult to remove  
than low speed dross.  
• The right side of the cut is more square than the left  
as viewed along the direction of travel.  
• Replace the nozzle when the orifice exit is eroded  
away or oval shaped.  
• Tilt the torch about 45° from the workpiece and hold  
the nozzle 1/8” (3.2mm) to 3/16” (4.8mm) above the  
workpiece for gouging.  
• After the problem is found, or if there is nothing  
apparently wrong, reset the machine by pressing  
the "Reset" button. (It is possible for electrical noise  
to trip the safety circuit on rare occasions. This  
should not be a regular occurrence.)  
• Clean spatter and scale from the nozzle and drag  
cup frequently.  
• If the machine does not reset or continues to trip,  
consult the Troubleshooting Section.  
• Use the proper cutting or gouging procedures  
referred to in Procedure Recommendations.  
PRO-CUT 80  
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B-6  
B-6  
OPERATION  
Thick Sections of Metal  
PILOT ARC DISCUSSION  
The PRO-CUT 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 intermittently. 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 work-  
piece and not for numerous starts without cutting.  
Torch Standoff  
Machine Output Setting  
45  
1/8"(3.2mm) thru  
3/16"(4.8mm)Standoff  
Output Setting  
Mid. thru Max. Range  
When the pilot arc is started, a slight impulse will be  
felt in the torch handle. This occurrence is normal and  
is the mechanism which starts the plasma arc. This  
impulse can also be used to help troubleshoot a "no  
start" condition.  
Output set above 45 Amps.  
• The best quality and consumable life will be  
obtained by holding the torch off the surface  
about 3/16"(4.8mm). Too long an arc may com-  
promise cut quality and consumable life. When  
the output setting is above mid-range, the noz-  
zle should NOT be dragged on the work.  
Failure to do so will result in shortened con-  
sumable life.  
PROCEDURE RECOMMENDATIONS  
When properly used, plasma arc cutting or gouging is  
a very economical process. Improper use will result in  
a very high operating cost.  
General - In All Cases  
• Use of the S22151 Drag Cup will maintain the  
proper standoff and eliminate nozzle double  
arcing.  
• Follow safety precautions as printed throughout  
this operating manual and on the machine.  
• 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 vertical 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.  
Thin Gauge Sheet Metal:  
Torch Standoff  
Machine Output Setting  
• Where possible, start the cut from the edge of  
the work piece.  
45  
• Keep moving! A steady speed is necessary.  
Do not pause.  
DRAG thru 1/16"(1.6mm)  
Standoff  
Output Setting  
Min. thru Mid. Range  
• Do not allow torch cable or body to contact hot  
surface.  
Output set below 45 Amps.  
• The nozzle may be dragged on the metal sur-  
face, touching it lightly to the surface after pierc-  
ing a hole. Current control should be set  
below the mid range.  
• Do not allow cable or body to contact hot sur-  
face.  
PRO-CUT 80  
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B-7  
B-7  
OPERATION  
h. 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.  
Suggestions for Extra Utility from the  
PRO-CUT System:  
WARNING  
i. Use only Lincoln consumable parts. These  
parts are patented and using any other  
replacement consumables may cause damage  
to the torch or reduce cut quality.  
ELECTRIC SHOCK CAN KILL.  
• Turn off machine at the disconnect  
switch on the front of the machine  
before tightening, cleaning or replacing  
consumables.  
MACHINE INTERFACE  
----------------------------------------------------------------------------  
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 Pro-Cut's safety circuit. When  
this happens turn the power off, remove the nozzle  
and electrode and use the electrode to rub against  
the inside bottom surface of the nozzle. This will  
help remove any oxide buildup. If the Parts-in-  
Place 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.  
The Pro-Cut 80 comes standard with a machine inter-  
face. Interface signals provided include: arc start, arc  
initiated, and arc voltage. These signals are accessi-  
ble through the 14 pin MS connector on the case  
front.  
ARC START:  
The Arc Start circuit allows for triggering of the power  
source to commence cutting. This circuit can be  
accessed through pins K and M of the 14 pin MS con-  
nector. The circuit has a 17 VDC nominal open circuit  
voltage and requires a dry contact closure to activate.  
ARC INITIATED:  
2. To improve consumable life, here are some sug-  
gestions that may be useful:  
The Arc Initiated circuit provides information as to  
when a cutting arc has transferred to the work piece.  
This circuit can be accessed through pins I and J of  
the 14 pin MS connector. The circuit provides a dry  
contact closure when the arc has transferred. Input to  
this circuit should be limited to 0.3 A for either  
120VAC or 30VDC.  
a. Never drag the nozzle on the work surface if  
the output control knob is set above 45 Amps.  
b. Make sure the air supply to the Pro-Cut is  
clean and free of oil. Use several extra in line  
filters if necessary.  
ARC VOLTAGE:  
The Arc Voltage circuit can be used for activating a  
torch height control. This circuit can be accessed  
through pins D and G of the 14 pin MS connector.  
The circuit provides full electrode to work arc voltage  
(no voltage divider, 335VDC maximum).  
c. Use the lowest output setting possible to make  
a good quality cut at the desired cut speed.  
d. Minimize dross buildup on the nozzle tip by  
starting the cut from the edge of the plate  
when possible.  
Arc Start  
K=2A  
M=4A  
Arc Initiated  
J=347  
I=348  
e. 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 perpen-  
dicular to the work and begin parallel move-  
ment.  
L
H
N
C
G=343  
D=344  
F
E
f. Reduce the number of pilot arc starts without  
transferring to the work.  
Arc Voltage  
14-PIN BOX RECEPTACLE, FRONT VIEW  
Users wishing to utilize the Machine Interface can  
order a K867 Universal Adapter (please adhere to the  
pin locations stated above) or manufacture a 14 pin  
MS connector cable assembly.  
g. Reduce the pilot arc time before transferring  
to the work.  
PRO-CUT 80  
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C-1  
C-1  
ACCESSORIES  
ALWAYS USE GENUINE LINCOLN GENERAL OPTIONS /  
ELECTRIC ELECTRODES AND ACCESSORIES  
VORTECH™ NOZZLES  
The following options/accessories are available for  
your PRO-CUT 80 from your local Lincoln Distributor.  
• Only Genuine Lincoln Electric consumables yield  
the best cutting performance for the PRO-CUT 80.  
K1681-1 Undercarriage - A valet style undercarriage  
with pull-out handle for machine only. Provides Torch  
and Work Cable storage.  
• The patented VORTECH™ nozzle provides an  
extra “kick” of swirl as the arc exits the nozzle which  
S22147-043 - VORTECH™ nozzle with an .043” (1.2  
mm) Orifice (for 35 - 60 Amps)  
improves cutting performance. No other nozzle has  
this capability or can match its performance.  
S22147-053 - VORTECH™ nozzle with an .053” (1.3  
mm) Orifice (for 60 - 85 Amps)  
S22147-082 - VORTECH™ nozzle with an .082” (2.1  
mm) Orifice (for Gouging at 60 - 85 Amps)  
S22149 - Electrode - replacement electrodes for cut-  
ting.  
S22150 - Shield Cup - This shields the torch tip and  
provides more visibility to the workpiece than the drag  
cup.  
•NOTE: the shield cup does not prevent the torch tip  
from touching the workpiece.  
S22151 - Drag Cup - The drag cup protects the torch  
by preventing the torch from touching the workpiece.  
K1571 Series - PCT 80 Torches come in 25’(7.6m)  
and 50’(15.2mm) lengths in either hand held or mech-  
anized versions.  
PRO-CUT 80  
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D-1  
D-1  
MAINTENANCE  
4. Obtain a high resistance and high wattage resistor  
(25-1000 ohms and 25 watts minimum). This resis-  
tor is not supplied with machine. NEVER USE A  
SHORTING STRAP FOR THIS PROCEDURE.  
WARNING  
ELECTRIC SHOCK can kill.  
• Have an electrician install and service  
this equipment.  
• Turn the input power off at the fuse  
box before working on equipment.  
• Do not touch electrically hot parts.  
• Prior to Performing preventative main-  
tenance, perform the following capaci-  
tor discharge procedure to avoid elec-  
tric shock.  
5. Locate the two capacitor terminals (large hex head  
cap screws) on the Power P.C. Board shown in  
Figure D.1.  
6. Use electrically insulated gloves and insulated pli-  
ers. Hold body of the resistor and connect resistor  
leads across the two capacitor terminals. Hold  
resistor in place for 10 seconds. DO NOT TOUCH  
CAPACITOR TERMINALS WITH YOUR BARE  
HANDS.  
---------------------------------------------------------------------  
INPUT FILTER CAPACITOR  
DISCHARGE PROCEDURE  
1. Turn off input power or disconnect input power  
lines.  
7. Repeat discharge procedure for the other capaci-  
tor .  
2. Remove the 5/16" hex head screws from the side  
and top of the machine and remove wrap-around  
machine cover.  
8. Check voltage across terminals of all capacitors  
with a DC voltmeter. Polarity of capacitor terminals  
is marked on PC board above terminals. Voltage  
should be zero. If any voltage remains, repeat this  
capacitor discharge procedure.  
3. Be careful not to make contact with the capacitor  
terminals that are located on the top and bottom of  
the Power Board on the right side of the machine.  
FIGURE D.1 — LOCATION OF INPUT FILTER CAPACITOR TERMINALS.  
POWER  
BOARD  
CAPACITOR  
TERMINALS  
POWER  
RESISTOR  
RIGHT SIDE OF MACHINE  
INSULATED  
PLIERS  
INSULATED  
GLOVES  
PRO-CUT 80  
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D-2  
D-2  
MAINTENANCE  
ROUTINE MAINTENANCE  
PERIODIC MAINTENANCE  
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.  
WARNING  
ELECTRIC SHOCK CAN KILL.  
• Turn off machine at the disconnect  
switch on the front of the machine  
before tightening, cleaning or replacing  
consumables.  
----------------------------------------------------------------------------  
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:  
Change consumables as required.  
1. Thermal Protection  
- Power, Output and Control printed circuit  
boards and heat sinks  
- Power switch  
- Main Transformer  
- Input Rectifier  
Two thermostats protect the machine from excessive  
operating temperatures. Excessive temperatures may  
be caused by a lack of cooling air or operating the  
machine beyond the duty cycle and output rating. If  
excessive operating temperatures should occur, the  
yellow thermal LED will light and the thermostat will  
prevent output voltage or current.  
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.  
Thermostats 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 prob-  
lem or air obstruction must be corrected.  
4. Check the air regulator filter to be sure it does not  
become clogged. The air filter on the machine is  
self draining and will not have to be emptied.  
5. Check the filter element every several months to  
see if it is clogged (weekly in very dirty environ-  
ments). Replace if necessary by first removing the  
two screws that attach the filter cage to the back  
panel assembly, then slide the cage away from the  
back of the machine and remove. Next, twist the  
clear filter bowl until it comes off (be careful not to  
lose the o-ring seated at the top of the bowl  
threads). Unscrew the filter element and replace  
with new element. Assemble parts in reverse order  
as described above.  
2. Filter Capacitor Conditioning (PRO-CUT 80, 400-  
460 VAC or 460-575 VAC)  
A protection circuit is included to monitor the voltage  
across filter capacitors C1 and C2. In the event that  
the capacitor voltage is too high, the protection circuit  
will prevent output. The protection circuit may prevent  
output providing all these circumstances are met:  
a. Machine is connected for 400-460 or 460-575  
VAC input.  
b. Machine did not have power applied for many  
months.  
c. Machine will not produce output when power is  
first switched on.  
6. 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.  
If these circumstances apply, the proper action is to  
switch the machine on and let it idle for up to 30 min-  
utes. This is required to condition the filter capacitors  
after an extended storage time. The protection circuit  
will automatically reset once the capacitor conditioning  
and resultant voltage levels are acceptable. It may be  
necessary to turn the power switch off and back on  
again after this period.  
PRO-CUT 80  
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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 your  
local Lincoln Authorized Field Service Facility.  
Step 1. LOCATE PROBLEM (SYMPTOM).  
Look under the column labeled “PROBLEM (SYMP-  
TOMS)”. 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 your  
local Lincoln Authorized Field Service Facility.  
Step 2. POSSIBLE CAUSE.  
The second column labeled “POSSIBLE CAUSE” lists  
the obvious external possibilities that may contribute  
to the machine symptom.  
WARNING  
ELECTRIC SHOCK CAN KILL.  
• Turn off machine at the disconnect  
switch on the front 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.  
PRO-CUT 80  
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E-2  
E-2  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
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 and  
machine connection.  
3. Disconnect input power at fuse  
panel and check line switch conti-  
nuity. Replace line switch if bad.  
4. Auxiliary transformer may be  
faulty.  
No Status indicators light 5 seconds 1. Auxiliary transformer may be  
after the power switch is turned on, faulty.  
but the fan operates.  
2. Disconnect input power from the  
machine. Check that connectors  
on harness between Control Bd.  
and Display Bd. are properly seat-  
ed.  
If all recommended possible areas of  
misadjustment have been checked  
and the problem persists, Contact  
your local Lincoln Authorized  
Field Service Facility.  
3. Possible faulty Control Board.  
All Status indicators remain lit imme- 1. The microprocessor has experi-  
diately after power up.  
enced a memory fault. Consult  
local Lincoln Field Service shop.  
All Status indicators begin to blink 1. Turn power off. Make sure recon-  
within 5 seconds after power up. nect is positioned correctly for the  
(Overvoltage Protection has been input voltage used. Wait at least 1  
activated). Remove Input power minute after power down before  
Immediately.  
re-connecting the machine.  
Reconnect machine,then restore  
power to Pro-Cut.  
2. Possible faulty Primary 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.  
PRO-CUT 80  
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E-3  
E-3  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
The Pro-Cut powers up properly but 1. Press Purge button on the front of  
there is no response when the trig- the Pro-Cut. If air does not flow,  
ger is pulled and only the POWER then:  
LED is lit.  
a. Auxiliary transformer may be  
faulty.  
b. The main gas solenoid assem-  
bly may be faulty. Check or  
replace.  
c. Possible faulty Output Power  
board.  
d. Possible faulty Control board.  
2. Check for continuity from the bulk-  
head connector to the molex. See  
Wiring Diagram.  
3. Remove the handles (or barrel) of  
the torch and examine all the con-  
nections. Pay attention to location  
of electrode lead mounting at back  
of torch head, broken trigger and  
solenoid leads.  
If all recommended possible areas of  
misadjustment have been checked  
and the problem persists, Contact  
your local Lincoln Authorized  
Field Service Facility.  
4. Check for proper trigger switch  
operation. Remove the torch cable  
assembly from the Pro Cut and  
test for continuity between 9 and 1  
at the quick connect when the trig-  
ger switch is depressed and no  
continuity when the switch is not  
depressed. Replace the trigger  
switch or torch cable if defective.  
5. Possible faulty Control board.  
6. Possible faulty Output Power  
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.  
PRO-CUT 80  
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E-4  
E-4  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
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  
at 70 psi (75 psi for a 50 ft. torch).  
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 and solenoid  
assembly.  
5. With machine turned off - input  
power removed, and torch and  
consumables connected - mea-  
sure resistance on Output Power  
board between B1 and B21. If  
>10Ω, possible fault in torch and  
cable assembly.  
If all recommended possible areas of  
misadjustment have been checked  
and the problem persists, Contact  
your local Lincoln Authorized  
Field Service Facility.  
6. Possible fault in Output 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.  
2. Make sure the air pressure is set  
at 70 psi (75 psi for a 50 ft. torch).  
3. Possible fault in Output Power board.  
1. Check the torch consumables to be  
sure they are in tight, not dirty or  
greasy and in good shape. Replace  
if necessary.  
The arc starts but sputters badly.  
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 at  
70 psi.  
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.  
PRO-CUT 80  
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E-5  
E-5  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
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. Check all connections to Output  
board.  
5. 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.  
PRO-CUT 80  
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E-6  
E-6  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
STATUS BOARD INDICATORS  
SYMPTOM  
CHECK  
Machine is unresponsive immediately after 1. There is a 4 second soft start period for pre-charging the input fil-  
power-up.  
ter capacitors. Wait until that time is up. The Power LED will light  
when ready. If not, refer to the first part of this section.  
The Air Low LED is lit  
1. Make sure there is at least 80 psi connected to the gas connec-  
tion at the back of the machine.  
2. Press the Purge button and set the regulator to 70 psi (75 psi for  
a 50 ft. torch). 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 Control board.  
The Safety LED is flashing  
1. Make sure there is a Lincoln torch and cable assembly connect-  
ed properly to the Pro-Cut bulk head connector.  
2. Check consumables for proper installation or excessive wear.  
Replace if excessively worn. If not, use a piece of fine emery  
cloth to remove any oxide buildup on the tip of the electrode.  
The Safety LED is lit and steady  
The Thermal LED is lit  
1. Press the Reset button. If torch and consumables are properly  
installed, the Safety LED should turn off. Normal cutting or goug-  
ing can resume.  
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. Possible faulty Control board.  
1. This is typically caused by connecting the auxiliary transformer  
input tap to the wrong voltage. Turn machine OFF and change  
lead to correct input voltage at reconnect panel.  
The “Ready”, “Air Low” and “Thermal” LED’s  
are flashing  
2. Possible faulty Control P. C. Board.  
PRO-CUT 80  
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E-7  
E-7  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENTS(S)  
RECOMMENDED  
COURSE OF ACTION  
CONSUMABLE RELATED SAFETY LED  
If the Safety LED is LIT AND STEADY, perform the following:  
Press the reset button. If the torch 1. If the reset button (when pressed)  
and consumables are properly does not turn the Safety LED off,  
installed, the Safety LED should turn the reset button or associated  
off.  
wiring may be faulty. See the  
wiring diagram.  
Try to recount the number of times 1. If this has occurred numerous  
that the Safety LED has come on lit times, clean consumables with a  
and steady with this particular set of piece of fine emery cloth to  
consumables.  
remove any oxide buildup on the  
tip of the electrode, or try replac-  
ing the electrode and nozzle.  
If all recommended possible areas of  
misadjustment have been checked  
and the problem persists, Contact  
your local Lincoln Authorized  
Field Service Facility.  
If the Safety LED is FLASHING, perform the following:  
Check the condition of the electrode. 1. Replace both electrode and noz-  
The maximum wear depth in the zle if electrode is excessively  
center of the electrode tip is approxi- worn. Otherwise, use a piece of  
mately .060" relative to the surround- fine emery cloth to remove any  
ing tip. A green and erratic arc will oxide buildup on the tip of the  
indicate definite electrode failure as electrode. Even if consumables  
explained in the "Consumable Life" appear to be in good working  
section of this manual.  
order, it is possible that they are  
the cause of the problem. Try  
replacing.  
Check the conditions of the inside of 1. If debris has collected, rub the  
the nozzle. Make sure that both the electrode on the inside bottom of  
electrode and nozzle are not dirty, the nozzle to remove any oxide  
oily, or corroded.  
layer that may have built up. If  
problems persist, try replacing  
consumables.  
NOTE: Make sure that consumables  
are Lincoln Electric brand consum-  
able parts. These parts are patented  
and using any other replacement  
consumables may cause damage to  
the torch or reduce cut quality. Also  
be sure to check that the nozzle is  
the correct part number (as identified  
on the top and side of the nozzle) for  
the Pro-Cut being used.  
Remove consumables from torch 1. If torch head is contaminated, take  
and check inside of torch head for a dry cotton swab and clean out  
contamination. Check incoming air- the pollutants. If needed, replace  
flow for contaminants.  
air filter and check/change air sup-  
ply. For more information, refer to  
the "Gas Input Connections" sec-  
tion in the manual.  
Make sure there is a Lincoln PCT 80  
torch connected properly to the Pro-  
Cut 55 and that the consumables are  
properly installed. Make sure the  
shield cup is hand tight. Do not use pli-  
ers or over-tighten.  
1. After verifying that the torch and  
consumables are properly set in  
place, and the problem still per-  
sists, 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.  
PRO-CUT 55  
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F-1  
G4239  
G4238  
F-1  
DIAGRAMS  
C H I N E  
O N F T R O F M A  
4 A  
2 A  
3 4 7  
3 4 8  
3 4 3  
3 4 4  
6 4  
6 2  
6 1  
B K - O U T  
B K - I N  
xxxxxxx  
ELEC  
C H I N E  
R E A R O F M A  
PRO-CUT 80  
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F-2  
F-2  
DIAGRAMS  
C H I N E  
O N F T R O F M A  
4 A  
2 A  
3 4 7  
3 4 8  
3 4 3  
3 4 4  
6 4  
6 2  
6 1  
xxxxxxx  
ELEC  
C H I N E  
R E A R O F M A  
PRO-CUT 55  
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Enhanced Diagram  
F-3  
F-3  
DIAGRAMS  
E N I H C A M F O T N O R F  
4 A  
2 A  
7
8
3 4  
3 4  
3
4
3 4  
3 4  
6 4  
6 2  
6 1  
xxxxxxx  
ELEC  
E N I H C A M F O R A E R  
PRO-CUT 55  
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F-4  
F-4  
DIAGRAMS  
E I N H C A M F O T N O R F  
4 A  
2 A  
7
8
3 4  
3 4  
3 4  
3
4
3 4  
6 4  
6 2  
6 1  
xxxxxxx  
ELEC  
E N I H C A M F O R A E R  
PRO-CUT 55  
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F-5  
F-5  
DIAGRAMS  
PRO-CUT 80  
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NOTES  
PRO-CUT 80  
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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  
SpanisAh VISO DE  
PRECAUCION  
French  
● No toque las partes o los electrodos ● Mantenga el material combustible  
● Protéjase los ojos, los oídos y el  
bajo carga con la piel o ropa moja-  
da.  
● Aislese del trabajo y de la tierra.  
fuera del área de trabajo.  
cuerpo.  
● Ne laissez ni la peau ni des vête-  
ments mouillés entrer en contact  
avec des pièces sous tension.  
● Gardez à l’écart de tout matériel  
inflammable.  
● Protégez vos yeux, vos oreilles et  
votre corps.  
ATTENTION  
● Isolez-vous du travail et de la terre.  
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 elec-  
trodos com a pele ou roupa molha-  
da.  
● Mantenha inflamáveis bem guarda- ● Use proteção para a vista, ouvido e  
dos.  
corpo.  
ATENÇÃO  
● Isole-se da peça e terra.  
Japanese  
Chinese  
Korean  
Arabic  
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE  
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.  
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y 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 ELEKTRODENEINSATZ DES HER-  
STELLERS. 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- ● N’opérez pas avec les panneaux  
tien.  
● Gardez la tête à l’écart des fumées.  
● Utilisez un ventilateur ou un aspira-  
teur pour ôter les fumées des zones  
de travail.  
ouverts ou avec les dispositifs de  
protection enlevés.  
ATTENTION  
German  
● Strom vor Wartungsarbeiten  
abschalten! (Netzstrom völlig öff-  
nen; 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 WEB SITE: www.lincolnelectric.com  
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