Tomahawk 1000, Operator'S Manual

Page 1: ...NOT INSTALL OPER ATE OR REPAIR THIS EQUIP MENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CON TAINED THROUGHOUT And most importantly think before you act and be careful For use with machines having Code Number 11581 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 World s...

Page 2: ...n in posi tions such as sitting or lying make certain the insulation is large enough to cover your full area of physical contact with work and ground 1 d Always be sure the work cable makes a good electrical con nection with the metal being cut or gouged The connection should be as close as possible to the area being cut or gouged 1 e Ground the work or metal to be cut or gouged to a good elec tri...

Page 3: ...d 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 5 b Always keep cylinders in an upright position securely chained to an undercarriage or fixed support 5 c Cylinders should be located Away fro...

Page 4: ...NOTES ...

Page 5: ...riés et non inflammables 4 Des gouttes de laitier en fusion sont émises de lʼarc de soudage Se protéger avec des vêtements de protection libres de lʼhuile tels que les gants en cuir chemise épaisse pan talons sans revers et chaussures montantes 5 Toujours porter des lunettes de sécurité dans la zone de soudage Utiliser des lunettes avec écrans lateraux dans les zones où lʼon pique le laitier 6 Elo...

Page 6: ...y important when identifying the correct replacement parts 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...

Page 7: ...eneral B 7 Suggestions for Extra Utility from the TOMAHAWK 1000 System B 8 Torch Part Configurations B 9 B 10 Machine Interface B 11 ________________________________________________________________________________ Accessories Section C ________________________________________________________________________ Maintenance Section D Safety Precautions D 1 Routine Maintenance D 1 Periodic Maintenance D...

Page 8: ...utting applications Based on U S National Electrical Code Ambient Temperature 30o C or Less Pilot Current 20 Amps CURRENT 40A 60A VOLTAGE 96VDC 104 VDC 208V 1 50 60 230V 1 50 60 208V 3 50 60 230V 3 50 60 460V 3 50 60 575V 3 50 60 Input Amperes Rated Output Circuit Breaker Delay Type 38 25 50 Duty Cycle 100 Duty Cycle 34 23 50 Duty Cycle 100 Duty Cycle 25 16 50 Duty Cycle 100 Duty Cycle 21 13 50 Du...

Page 9: ...high frequency interference into the TOMA HAWK 1000 can be minimized 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 4 When t...

Page 10: ...line filter be installed in the air supply line ahead of the air connection to the TOMA HAWK 1000 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...

Page 11: ...mperature 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 Duty Cycle The duty...

Page 12: ...asma cut ting uncomplicated 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 Light weight and portable design for industrial use Continuous control 20 60 amps Reliable touch start mechanism for plasma arc initi ation Rapid arc restrike for fast cutting of expanded metal Input over voltage protect...

Page 13: ...ckness inches Recommended Torch Travel Speed IPM Tomahawk 1000 0 1 4 1 2 3 4 1 1 1 4 1 1 2 Recommended Cut 19 IPM Max Cut 10 IPM Sever Cut 5 IPM CONSUMABLE LIFE The expected life for the TOMAHAWK 1000 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...

Page 14: ...needs to be turned OFF then ON again to restart 4 Thermal yellow LED 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 possible 5 Gas Pressure yellow LED The Input Gas pressure is out of range The ma...

Page 15: ...utton Set the desired cutting current using the Output Current knob To start the selected process pull the torch trigger making sure you are not aiming the torch in an unsafe manner Once the process is completed releasing the torch trigger will cause the plasma arc to turn off The gas flow will continue allowing the torch to cool TOMAHAWK 1000 WARNING 7 Primary Air Gas Pressure Gauge and Regulator...

Page 16: ...to maximize the output in order to remove the most material in a short amount of time B 6 OPERATION B 6 TOMAHAWK 1000 The Post Flow time is proportional to the selected cutting current and it is divided into 4 time ranges Pilot Arc 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 af...

Page 17: ...ozzle frequently During operation if the Parts in Place Yellow LED light together 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 Check the conditions on the inside of the nozzle If debris has collected rub the inside of the nozzle to remove any oxide layer that ma...

Page 18: ...HAWK 1000 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 m...

Page 19: ...istent 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 There are two types of contact cutting 1 Direct ...

Page 20: ...eld 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 TOMAHAWK 1000 www lincolnelectric com 3 10 ...

Page 21: ...g arc has transferred to the work piece This circuit can be accessed through pins I and J of the 14 pin connector The circuit provides a dry con tact closure when the arc has transferred Input to this circuit should be limited to 0 3 A for either 120VAC or 30VDC 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 o...

Page 22: ... to 33 in diameter 77mm to 838mm TORCHES The following replacement or optional torches are available K2848 1 LC65 Handheld Plasma Torch 25 7 5m K2848 2 LC65 Handheld Plasma Torch 50 15m K2848 3 LC65M Mechanized Plasma Torch 25 7 5m 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...

Page 23: ...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 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 bo...

Page 24: ...ymptom 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 If you do not understand or are unable to perform the Recommended Course of Action safely contact you local Lincoln Authorized Field Service Facility HOW TO USE TROUBLESHOOTING GUIDE Service and Repair should on...

Page 25: ...ed on No Status indicators light 5 seconds after the power switch is turned on but the fan operates The Thermal LED does not go out 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 1 Check the input power to be sure it is on 2 Check the power line fuses or b...

Page 26: ...ly but there is no response when the trigger is pulled and only the POWER LED is lit 1 Turn the output knob to purge zone on the front of the TOMA HAWK 1000 If air does not flow 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 swit...

Page 27: ...y 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 Control board 1 Check the torch consumables to be sure they are in tight not dirty or greasy and in good shape ...

Page 28: ...TMENTS RECOMMENDED COURSE OF ACTION Pilot arc starts but will not transfer when brought near work 1 Check work lead connection for 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 3 Make sure work piece is clean and dry Remove any scale rust or dross 4 Check all connections to Control board 5...

Page 29: ...e while the air is OFF 3 Possible faulty Pressure Switch 4 Possible faulty Control board 1 Verify Torch consumables are in good condition and properly installed If torch and consumables are properly installed the Yellow LED should turn off The unit may be required to have the input power turned off then back on Normal cutting or gouging can resume 1 The machine s thermostat has tripped due to exce...

Page 30: ...allow troubleshooting as necessary 2 To restore the machine Turn OFF the Power switch Check the correct placement of the Torch Head consumables and parts Check the Torch electrical connections Turn ON the machine No pilot arc established On Green LED On Yellow LED On Yellow LED On Yellow LED 1 This occurs if the machine is turned ON or if it is restarted after Thermal reset with the Torch Trigger ...

Page 31: ...t may not be accurate for all machines covered by this manual The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels If the diagram is illegible write to the Service Department for a replacement Give the equipment code number ...

Page 32: ...electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da 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 Berühren Sie keine stromführenden Teile oder Elektrode...

Page 33: ...gute Be und Entlüftung des Arbeitsplatzes Mantenha seu rosto da fumaça Use ventilação e exhaustão para remover fumo da zona respiratória Turn power off before servicing Desconectar el cable de ali mentación de poder de la máquina antes de iniciar cualquier servicio Débranchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom völlig öff nen Maschine anhalten Não opere co...

Page 34: ...s 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 World s Leader in Welding and Cutting Products ...