Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safety in mind. However,your overall safety can beincreased by proper installation... and thoughtful operation onyour part. DO NOT INSTALL,OPERATE OR REPAIR THISEQUIPMENT WITHOUT READ-ING THIS MANUAL AND THESAFETY PRECAUTIONS CON-TAINED THROUGHOUT. And,most importantly, think beforeyou act and be careful.
For use with machines having Code Number: 11579
• Sales and Service through Subsidiaries and Distributors Worldwide •
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDRENAWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.Read and understand the following safety highlights. For additional safety information it is strongly recommended that youpurchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box351040, Miami, Florida 33135 or CSA Standard W117.2. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR PROCEDURES AREPERFORMED ONLY BY QUALIFIED INDIVIDUALS.
CUTTING SPARKS cancause fire or explosion.4.a. Remove fire hazards from the plasma cut-ting or gouging area. If this is not possible, coverthem to prevent the cutting or gouging sparksfrom starting a fire. Remember that welding
sparks and hot materials from plasma cutting or gouging caneasily go through small cracks and openings to adjacentareas. Avoid cutting or gouging near hydraulic lines. Have afire extinguisher readily available.
4.b. Where compressed gases are to be used at the job site, spe-cial precautions should be used to prevent hazardous situa-tions. Refer to “Safety in Welding and Cutting” (ANSIStandard Z49.1) and the operating information for the equip-ment being used.
ARC RAYS can burn.2.a. Use safety glasses and a shield with the prop-er filter and cover plates to protect your eyes fromsparks and the rays of the arc when performing orobserving plasma arc cutt ing or gouging.Glasses,headshield and filter lens should conformto ANSI Z87. I standards.
2.b. Use suitable clothing including gloves made from durableflame-resistant material to protect your skin and that of yourhelpers from the arc rays.
2.c. Protect other nearby personnel with suitable non-flammablescreening and/or warn them not to watch the arc nor exposethemselves to the arc rays or to hot spatter or metal.
ELECTRIC SHOCK cankill.1.a. The electrode and work (or ground) circuitsare electrically “hot” when the power source is on.Do not touch these “hot” parts with your bare skinor wet clothing. Wear dry, hole-free gloves to
insulate hands.
1.b. When the power source is operating voltages in excess of250 volts are produced. This creates the potential for seriouselectrical shock - potentially even fatal.
1.c. Insulate yourself from work and ground using dry insulation.When cutting or gouging in damp locations, on metal frame-work such as floors, gratings or scaffolds and when in posi-tions such as sitting or lying, make certain the insulation islarge enough to cover your full area of physical contact withwork and ground.
1.d. Always be sure the work cable makes a good electrical con-nection with the metal being cut or gouged. The connectionshould be as close as possible to the area being cut orgouged.
1.e. Ground the work or metal to be cut or gouged to a good elec-trical (earth) ground.
1.f. Maintain the plasma torch, cable and work clamp in good,safe operating condition. Replace damaged insulation.
1.g. Never dip the torch in water for cooling or plasma cut orgouge in or under water.
1.h. When working above floor level, protect yourself from a fallshould you get a shock.
1.i. Operate the pilot arc with caution. The pilot arc is capable ofburning the operator, others or even piercing safety clothing.
1.j. Also see Items 4c and 6.
WARNING PLASMA CUTTING or GOUGING can be hazardous.
FUMES AND GASEScan be dangerous.3.a. Plasma cutting or gouging may producefumes and gases hazardous to health. Avoidbreathing these fumes and gases. When cutting
or gouging, keep your head out of the fumes. Use enoughventilation and/or exhaust at the arc to keep fumes andgases away from the breathing zone. When plasma cuttingor gouging on lead or cadmium plated steel and othermetals or coatings which produce highly toxic fumes,keep exposure as low as possible and within applicableOSHA PEL and ACGIH TLV limits using local exhaust ormechanical ventilation. In confined spaces or in somecircumstances, outdoors, a respirator may be required.Additional precautions are also required when weldingon galvanized steel.
3. b. The operation of plasma cutting or gouging fume controlequipment is affected by various factors including proper useand positioning of the equipment, maintenance of the equip-ment and the specific procedure and application involved.Worker exposure level should be checked upon installationand periodically thereafter to be certain it is within applicableOSHA PEL and ACGIH TLV limits.
3.c. Do not use plasma cutting or gouging equipment in locationsnear chlorinated hydrocarbon vapors coming from degreas-ing, cleaning or spraying operations. The heat and rays of thearc can react with solvent vapors to form phosgene, a highlytoxic gas, and other irritating products.
3.d. Gases used for plasma cutting and gouging can displace airand cause injury or death. Always use enough ventilation,especially in confined areas, to insure breathing air is safe.
3.e. Read and understand the manufacturerʼs instructions for thisequipment and follow your employerʼs safety practices.
iSAFETYi
Refer to http://www.lincolnelectric.com/safety for additional safety information.
4.c. When not cutting or gouging, make certain no part of the elec-trode circuit is touching the work or ground. Accidental contactcan cause overheating and create a fire hazard.
4.d. Do not cut or gouge tanks, drums or containers until the propersteps have been taken to insure that such procedures will notcause flammable or toxic vapors from substances inside. Theycan cause an explosion even though they have been“cleaned.” For information purchase “Recommended SafePractices for the Preparation for Welding and Cutting ofContainers and Piping That Have Held HazardousSubstances”, AWS F4.1 from the American Welding Society(see address above).
4.e. Vent hollow castings or containers before heating, cutting orgouging. They may explode.
4.f. Do nor fuel engine driven equipment near area where plasmacutting or gouging.
4.g. Sparks and spatter are thrown from the plasma arc. Wearsafety glasses, ear protection and oil free protective garmentssuch as leather gloves, heavy shirt, cuffless trousers, highshoes and a cap over your hair. Wear ear plugs when cuttingor gouging out of position or in confined places. Always wearsafety glasses with side shields when in a cutting or gougingarea.
4.h. Connect the work cable to the work as close to the cutting orgouging area as practical. Work cables connected to the build-ing framework or other locations away from the cutting orgouging area increase the possibility of the current passingthrough lifting chains, crane cables or other alternate circuits.This can create fire hazards or overheat lifting chains orcables until they fail.
4.I. Read and follow NFPA 51B “ Standard for Prevention DuringWelding, Cutting and Other Hot Work”, available from NFPA, 1Batterymarch Park,PO box 9101, Quincy, Ma 022690-9101.
FOR ELECTRICALLYpowered equipment.6.a. Turn off input power using the disconnectswitch at the fuse box before working on theequipment.
6.b. Install equipment in accordance with the U.S. NationalElectrical Code, all local codes and the manufacturerʼs rec-ommendations.
6.c. Ground the equipment in accordance with the U.S. NationalElectrical Code and the manufacturerʼs recommendations.
CYLINDER may explodeif damaged.5.a. Use only compressed gas cylinders contain-ing the correct gas for the process used andproperly operating regulators designed for thegas and pressure used. All hoses, fittings, etc.
should be suitable for the application and maintained in goodcondition.
5.b. Always keep cylinders in an upright position securelychained to an undercarriage or fixed support.
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.
5.d. Never allow any part of the electrode, torch or any otherelectrically “hot” parts to touch a cylinder.
5.e. Keep your head and face away from the cylinder valve outletwhen opening the cylinder valve.
5.f. Valve protection caps should always be in place and handtight except when the cylinder is in use or connected foruse.
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 inCylinders,”available from the Compressed Gas Association1235 Jefferson Davis Highway, Arlington, VA 22202.
ELECTRIC AND MAGNETICFIELDSmay be dangerous8.a. Electric current flowing through any con-ductor causes localized Electric and MagneticFields (EMF). Cutting or gouging current cre-ates EMF fields around torch cables and cuttingmachines.
8.b. EMF fields may interfere with some pacemakers, so opera-tors having a pacemaker should consult their physicianbefore cutting or gouging.
8.c. Exposure to EMF fields during cutting or gouging may haveother health effects which are now not known.
8d. All operators should use the following procedures in order tominimize exposure to EMF fields from the cutting or gougingcircuit:
8.d.1. Route the torch and work cables together - Securethem with tape when possible.
8.d.2. Never coil the torch cable around your body.
8.d.3. Do not place your body between the torch andwork cables. If the torch cable is on your right side,the work cable should also be on your right side.
8.d.4. Connect the work cable to the workpiece as close aspossible to the area being cut or gouged.
8.d.5. Do not work next to cutting power source.
PLASMA ARC can injure.
7.a. Keep your body away from nozzle andplasma arc.
7.b. Operate the pilot arc with caution. The pilot arc is capable ofburning the operator, others or even piercing safety clothing.
iiSAFETYii
NOTES
ivSAFETYiv
PRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques qui parraissent dans cemanuel aussi bien que les précautions de sûreté générales suiv-antes:
Sûreté Pour Soudage A LʼArc1. Protegez-vous contre la secousse électrique:
a. Les circuits à lʼélectrode et à la piéce sont sous tensionquand la machine à souder est en marche. Eviter toujourstout contact entre les parties sous tension et la peau nueou les vétements mouillés. Porter des gants secs et sanstrous pour isoler les mains.
b. Faire trés attention de bien sʼisoler de la masse quand onsoude dans des endroits humides, ou sur un planchermetallique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grandepartie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câblede soudage et la machine à souder en bon et sûr étatdefonctionnement.
d.Ne jamais plonger le porte-électrode dans lʼeau pour lerefroidir.
e. Ne jamais toucher simultanément les parties sous tensiondes porte-électrodes connectés à deux machines à souderparce que la tension entre les deux pinces peut être letotal de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source decourant pour soudage semi-automatique, ces precautionspour le porte-électrode sʼapplicuent aussi au pistolet desoudage.
2. Dans le cas de travail au dessus du niveau du sol, se protégercontre les chutes dans le cas ou on recoit un choc. Ne jamaisenrouler le câble-électrode autour de nʼimporte quelle partiedu corps.
3. Un coup dʼarc peut être plus sévère quʼun coup de soliel,donc:
a. Utiliser un bon masque avec un verre filtrant appropriéainsi quʼun verre blanc afin de se protéger les yeux du ray-onnement de lʼarc et des projections quand on soude ouquand on regarde lʼarc.
b. Porter des vêtements convenables afin de protéger lapeau de soudeur et des aides contre le rayonnement delʻarc.
c. Protéger lʼautre personnel travaillant à proximité ausoudage à lʼaide dʼécrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de lʼarc desoudage. Se protéger avec des vêtements de protection libresde 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 desoudage. Utiliser des lunettes avec écrans lateraux dans leszones où lʼon pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin deprévenir tout risque dʼincendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé dela masse. Un court-circuit accidental peut provoquer unéchauffement et un risque dʼincendie.
8. Sʼassurer que la masse est connectée le plus prés possiblede la zone de travail quʼil est pratique de le faire. Si on placela masse sur la charpente de la construction ou dʼautresendroits éloignés de la zone de travail, on augmente le risquede voir passer le courant de soudage par les chaines de lev-age, câbles de grue, ou autres circuits. Cela peut provoquerdes risques dʼincendie ou dʼechauffement des chaines et descâbles jusquʼà ce quʼils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.Ceci est particuliérement important pour le soudage de tôlesgalvanisées plombées, ou cadmiées ou tout autre métal quiproduit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenantdʼopérations de dégraissage, nettoyage ou pistolage. Lachaleur ou les rayons de lʼarc peuvent réagir avec les vapeursdu solvant pour produire du phosgéne (gas fortement toxique)ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté,voir le code “Code for safety in welding and cutting” CSAStandard W 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POURLES MACHINES À SOUDER ÀTRANSFORMATEUR ET ÀREDRESSEUR
1. Relier à la terre le chassis du poste conformement au code delʼélectricité et aux recommendations du fabricant. Le dispositifde montage ou la piece à souder doit être branché à unebonne mise à la terre.
2. Autant que possible, Iʼinstallation et lʼentretien du poste seronteffectués par un électricien qualifié.
3. Avant de faires des travaux à lʼinterieur de poste, la debranch-er à lʼinterrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leurplace.
vv
Thank You for selecting a QUALITY product by Lincoln Electric. We want youto take pride in operating this Lincoln Electric Company product••• as much pride as we have in bringing this product to you!
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep ithandy 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:
WARNINGThis statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.
CAUTION
Please Examine Carton and Equipment For Damage ImmediatelyWhen this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claimsfor material damaged in shipment must be made by the purchaser against the transportation company at thetime the shipment is received.
Please record your equipment identification information below for future reference. This information can befound on your machine nameplate.
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 youhave recorded above. The code number is especially important when identifying the correct replacement parts.
CUSTOMER ASSISTANCE POLICYThe 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 LincolnElectric for advice or information about their use of our products. We respond to our customers based on the best information in our posses-sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor-mation or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customerʼs particular purpose,with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating orcorrecting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter anywarranty with respect to the sale of our products.
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the controlof, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained inapplying these types of fabrication methods and service requirements.
Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.comfor any updated information.
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 “Support” and then “Register
Your Product”. Please complete the form and submit your registration.
Operation.........................................................................................................................Section BSafety Precautions ...............................................................................................................B-1Description ...........................................................................................................................B-1Preheat Temperature for Plasma Cutting.............................................................................B-1User Responsibility...............................................................................................................B-2Operational Features and Controls ......................................................................................B-2Design Features and Advantages ........................................................................................B-2Cutting Capability .................................................................................................................B-3Consumable Life ..................................................................................................................B-3Limitations ............................................................................................................................B-4Controls and Settings ...................................................................................................B-4, B-5Cutting Process ............................................................................................................B-5, B-6Torch ....................................................................................................................................B-7Pilot Arc Discussion..............................................................................................................B-7Procedure Recommendations..............................................................................................B-7
General .........................................................................................................................B-7Suggestions for Extra Utility from the TOMAHAWK™ 375 AIR System .......................B-8
Torch Part Configurations ....................................................................................................B-9________________________________________________________________________________
REQUIRED GAS FLOW RATE REQUIRED GAS INLET PRESSURE
PHYSICAL DIMENSIONS
TECHNICAL SPECIFICATIONS -TOMAHAWK™ 375 AIR
Standard Voltage
Duty Cycle100%60%35%
CurrentRange
10-25 Amps
AC Input Voltage
at60 Hertz
230V-1Ø 208V-1Ø
Fuse(Super Lag)
Circuit Breaker(Delay Type)
20 AMPS #12 (3.3 mm2)
2 Input Supply Wires 1 Ground Wire
#12 (3.3 mm2)
Type S, SO, ST, STO or extrahard usage input cord
AWG (IEC) Sizes
Depth
18.9 in.480 mm
Width
8.5 in.215 mm
Height
15.2 in.385 mm
Open CircuitVoltage460 VDC
For all plasma cutting applicationsBased on U.S. National Electrical Code
Ambient Temperature 30oC or Less
Pilot Current
12 Amps
CURRENT AMPS13 A18 A25 A
VOLTAGE VOLTS85.2 VDC87.2 VDC90 VDC
208V, 230V ±10% / 1 / 60Hz
70 PSI @ 125-200 SCFH( 5 Bar. @ 80±20 LITERS/MIN.)
80 to 110 PSI(6 Bar. to 7.5 Bar.)
25 A
Output Input Cord Plug Size
6-50P
TOMAHAWK™ 375 AIR
TEMPERATURE RANGESOPERATING TEMPERATURE RANGE
-10°C to +40°CSTORAGE TEMPERATURE RANGE
-10°C to +40°C
A-2INSTALLATION
TOMAHAWK™ 375 AIR
A-2
Read entire Installation Section before installing theTOMAHAWK™ 375 AIR.
SAFETY PRECAUTIONS
ELECTRIC SHOCK CAN KILL.• Only qualified personnel
should install this machine.• Turn the input power OFF
at the disconnect switch or fuse box and dischargeinput capacitors beforeworking inside the equip-ment.
• Do not touch electrically hot parts.• Turn the TOMAHAWK™ 375 AIR Power
Switch OFF when connecting power cordto input power.
___________________________________________
SELECT PROPER LOCATION
Place the TOMAHAWK™ 375 AIR where clean coolair can freely circulate in and out the side louvers. Dirt,dust or any foreign material that can be drawn into themachine should be kept at a minimum. Failure toobserve these precautions can result in excessiveoperating temperatures and nuisance shutdown of themachine.
A source of clean, dry air or nitrogen must be suppliedto the TOMAHAWK™ 375 AIR when using externalair supply. Oil in the air is a severe problem and mustbe avoided. The supply pressure must be between 80and 150 psi. The flow rate is approximately 4.0 cfm(113 l/min.). Failure to observe these precautionscould result in excessive operating temperatures ordamage to the torch.
STACKING
The TOMAHAWK™ 375 AIR cannot be stacked.
TILTING
The TOMAHAWK™ 375 AIR must be placed on a sta-ble, level surface so it will not topple over.
HIGH FREQUENCY INTERFERENCEPROTECTION
The TOMAHAWK™ 375 AIR employs a touch startmechanism for arc initiation which eliminates high fre-quency emissions from the machine as compared withspark gap and solid state type high frequency genera-tors. Keep in mind, though, that these machines maybe used in an environment where other high frequen-cy generating machines are operating. By taking thefollowing steps, high frequency interference into theTOMAHAWK™ 375 AIR can be minimized
(1) Make sure the power supply chassis is connectedto a good earth ground. The work terminal grounddoes NOT ground the machine frame.
(2) Keep the work clamp isolated from other workclamps that have high frequency.
(3) If the work clamp cannot be isolated, then keepthe clamp as far as possible from other workclamp connections.
(4) When the machine is enclosed in a metal building,several good earth driven electrical groundsaround the periphery of the building are recom-mended.
Failure to observe these recommended installationprocedures may cause improper function of the TOM-AHAWK™ 375 AIR or possibly even damage to thecontrol system or power supply components.
INPUT ELECTRICAL CONNECTIONS
The TOMAHAWK™ 375 AIR is rated for 208VAC and230VAC input voltage. Before installing the machine,check that input supply voltage, phase, and frequencyare the same as the machine's voltage, phase, andfrequency as specified on the machine's rating plate.
• The TOMAHAWK™ 375 AIR should be connectedonly by a qualified electrician. Installation should bemade in accordance with local codes.
For use on engine drives, keep in mind the aboveinput draw restrictions and the following precaution.
The TOMAHAWK™ 375 AIR can be operated onengine driven generators as long as the 230 volt auxil-iary meets the following conditions:
• The AC waveform peak voltage is below 400 volts.• The AC waveform frequency is between 55 and 65 Hz.• The RMS voltage of the AC waveform is always
greater than 208VAC.
WARNING
A-3INSTALLATION
TOMAHAWK™ 375 AIR
A-3
The following Lincoln engine drives meet these condi-tions when run in the high idle mode:Outback 180, Ranger 225, 250, 250LPG, 305G and305D engine drives. Vantage 300, 400, 500 and Air Vantage engine drives.
Operation of the TOMAHAWK™ 375 AIR is not rec-ommended on engine drives not conforming to theseconditions. Such combinations may overvoltage theTOMAHAWK™ 375 AIR power source.
GAS INPUT CONNECTIONS(External Air Supply)
Supply the TOMAHAWK™ 375 AIR with clean com-pressed air or nitrogen.
• Supply pressure must be between 80 psi and 110 psi.
• Flow rate should be approximately 125 - 200SCFH (80 ±20 L/min).
NOTE: Oil in the air supply to the TOMAHAWK™ 375AIR can cause severe problems. Use only aclean air supply.
• Compressed gas can be supplied either through the airfitting supplied with the machine or through the 1/4-19BSPP thread at the rear of the machine. To use the airfitting supplied with the machine (packaged in the con-sumable kit), apply teflon tape to the fitting threads andinstall the fitting in the port at the rear of the machine.
• If compressed air is being used, it is highly recom-mended that an in line filter be installed in the airsupply line ahead of the air connection to the TOMA-HAWK™ 375 AIR.
• A standard nominal 5 micron in line filter is recom-mended; however, for optimum performance, selecta prefilter with a 3 micron absolute rating.
If these filter ratings are unavailable, anything with arating less than, or equal to, 20 micron would beacceptable to use. In line filter elements will generallyfilter the air with little restriction to the airflow until theelement is about 75% contaminated. After this point,there will be a noticeable pressure drop in the line.Filter elements should be replaced when a pressuredrop of 8-10 psi is indicated; however, for optimumperformance of the TOMAHAWK™ 375 AIR, the filterelement should be replaced at or before the pressuredrop reaches 8 psi. Be sure to select a filter that willaccommodate the necessary flow rating for the TOM-AHAWK™ 375 AIR as specified in the Installation sec-tion of this instruction manual under the Gas InputConnections heading.
NOTE: When using nitrogen gas from a cylinder, thecylinder must have a pressure regulator.
• Maximum psi from a nitrogen gas cylinder tothe TOMAHAWK™ 375 AIR regulator shouldnever exceed 110 psi.
• Install a hose between the nitrogen gas cylin-der regulator and the TOMAHAWK™ 375 AIRgas inlet.
CYLINDER could explode if damaged.
• Keep cylinder upright andchained to a fixed support.
• Keep cylinder away from areaswhere it could be damaged.
• Never lift machine with cylinderattached.
• Never allow the cutting torch to touch the cylinder.
• Keep cylinder away from live electricalparts.
• Maximum inlet pressure 110 psi.------------------------------------------------------------------------
OUTPUT CONNECTIONS
TorchThe TOMAHAWK™ 375 AIR is sent from the factorywith a cutting torch and work clamp installed. Thework clamp must be securely connected to the workpiece. If the work piece is painted or extremely dirty itmay be necessary to expose the bare metal in orderto make a good electrical connection.
Built-In CompressorThis machine has a built-in compressor that allowsoperation in areas where an air supply is not avail-able. Only input voltage is necessary! The compres-sor provides a fixed pressure.
Read and understand this entire section before oper-ating the machine.
WARNING
B-1OPERATION
TOMAHAWK™ 375 AIR
B-1
SAFETY PRECAUTIONS DESCRIPTION
The TOMAHAWK™ 375 AIR is a constant current,continuous control plasma cutting power source. Itprovides superior and reliable starting characteristics,cutting visibility and arc stability. The control systemhas a safety mechanism to insure that the nozzle andelectrode are in place before cutting or gouging. Thisis extremely important due to the high voltagesinvolved.
The TOMAHAWK™ 375 AIR comes standard with anair regulator and pressure gauge. The machine alsocomes with an input power cord, Hand-held torch witha 10' cable length. Consumables are included witheach TOMAHAWK™ 375 AIR purchase so that cut-ting can begin right out of the box. Consumables canalso be ordered as individual packages.
The TOMAHAWK™ 375 AIR initiates the plasma arcwith a simple, yet reliable, touch start mechanism.This system eliminates many of the failure problemsassociated with hi-frequency start systems.
PREHEAT TEMPERATURE FORPLASMA CUTTING
Preheat temperature control is not necessary in mostapplications when plasma arc cutting or gouging.Preheat temperature control may be necessary on highcarbon alloy steels and heat treated aluminum for crackresistance and hardness control. Job conditions, pre-vailing codes, alloy level, and other considerations mayalso require preheat temperature control. The followingminimum preheat temperature is recommended as astarting point. Higher temperatures may be used asrequired by the job conditions and/or prevailing codes.If cracking or excessive hardness occurs on the cutface, higher preheat temperature may be required. Therecommended minimum preheat temperature for platethickness up to 1/2" (12.7mm) is 70°F (21.1°C).
ELECTRIC SHOCKcan kill.
• Do not touch electrically live partsor electrode with skin or wetclothing.
• Insulate yourself from work andground.
• Always wear dry insulating gloves.
FUMES AND GASEScan be dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust toremove fumes from breathingzone.
WELDING, CUTTING and GOUGING SPARKScan cause fire or explosion
• Keep flammable material away.
• Do not weld, cut or gouge oncontainers that have held combustibles.
Observe additional Safety Guidelines detailed inthe beginning of this manual.
WARNING
ARC RAYScan burn.
• Wear eye, ear and bodyprotection.
PLASMA ARC can injure
• Keep your body away from nozzleand plasma arc.
• Operate the pilot arc with caution. The pilot arc is capable of burning the operator, others or even piercing safety clothing.
B-2OPERATIONB-2
USER RESPONSIBILITY
Because design, fabrication, erection and cutting vari-ables affect the results obtained in applying this typeof information, the serviceability of a product or struc-ture is the responsibility of the user. Variation such asplate chemistry, plate surface condition (oil, scale),plate thickness, preheat, quench, gas type, gas flowrate and equipment may produce results different thanthose expected. Some adjustments to proceduresmay be necessary to compensate for unique individ-ual conditions. Test all procedures duplicating actualfield conditions.
DESIGN FEATURES ANDADVANTAGES
The TOMAHAWK™ 375 AIR design makes plasmacutting uncomplicated. This list of design features andadvantages will help you understand the machine'stotal capabilities so that you can get maximum usefrom your machine.
- Light weight and portable design for industrial use.
- Continuous control, 10 - 25 amps.
- Reliable touch start mechanism for plasma arc initi-ation.
- Rapid arc restrike for fast cutting of expanded metal.
- Input over voltage protection.
- Bright 3.0 second timed pilot arc.
- Purge section on output dial.
- Air regulator and pressure gage included.
- Internal water separator included.
- Parts-in-Place mechanism to detect proper installa-tion of consumables and torch.
- Preflow/Postflow timing. Preflow is eliminated if arcis re-initiated in Postflow.
- Thermostatic Protection.
- Solid state over-current protection.
- Unique electrode and nozzle design for optimumcooling and long life.
TOMAHAWK™ 375 AIR
B-3OPERATIONB-3
CUTTING CAPABILITY
The TOMAHAWK™ 375 AIR is rated at 25 amps, at35% duty cycle on a 10 minute basis. If the duty cycleis exceeded, a thermal protector will shut off the out-put of the machine until it cools to the normal operat-ing temperature.
Figure B.1 shows the cut capacity of the TOMA-HAWK™ 375 AIR when cutting mild steel. (The graphplots cut thickness vs. torch travel speed with a torchstandoff of 0.15".)
TOMAHAWK™ 375 AIR
TOMAHAWK 375 AIRTOMAHAWK 375 AIR
CONSUMABLE LIFE
The expected life for the TOMAHAWK™ 375 AIR'selectrode under normal operating conditions isapproximately 1000 starts/cuts. An erosion of .060" istypical for end of electrode life, however, the electrodelife may last longer. A green and erratic arc will indi-cate definite electrode failure and the electrode shouldbe replaced immediately.
It is recommended that consumables be replaced incomplete sets. (Example: Electrode and Nozzle). Thiswill maximize the performance of the TOMAHAWK™375 AIR system.
Figure B.1
CONTROLS AND SETTINGS(Figure B.2)
TOMAHAWK™ 375 AIR front command panel.FIGURE B.2
1. Output Current Knob: Potentiometer used to setthe output current used during cutting. Refer tothe Technical Specification section for more infor-mation about the machineʼs rated current range.
Air Purge: The Output Current Knob completelyrotated counterclockwise enables the air purgefunction. A five minute timeout stops the purgefunction; this will occur only if the Output CurrentKnob remains in the purge mode for an extendedtime.
2. Power ON/OFF green LED: Illuminates whenthe machine is ON.
3. Output red LED: See the following table.
4. Thermal yellow LED: See the following table.
VAA
25MIN15 TOMAWK375AIR
WARNINGAIRI0
1
2
3
4 5
6
V
A
A
25
MIN
15
TOMAHAWK375AIR
R
WARNING
AIR
I
0
1
2
3
4 5
6
B-4OPERATIONB-4
TOMAHAWK™ 375 AIR
LEDsOutput Thermal(Red) (Yellow)On OffOn On
Off On
Off Blink
Blink Off
Description
The cutting torch is energized.Part in place error: the retainingcap is not properly Attached.
To restore the machine:• Install the torch retaining cap
firmly in place.• Wait for 5 seconds; during this
time the output and thermalLEDʼs blinks alternately.
• After 5 seconds the machine isautomatically restored and readyto operate.
The machine is overheated andthe output has been disabled.This usually occurs when the dutycycle of the machine has beenexceeded. Leave the machine Onto allow the internal components tocool. When the thermal LED turnsoff, normal operation is again pos-sible.
Power undervoltage error: themachine is disabled. When thepower returns to the correct range,the machine will restart automati-cally.
Low air pressure error.
To check / adjust the air pressure(see recommended values in theTechnical Specifications of thismanual):• Put the machine in Purge mode
[1].• Check and adjust the air pres-
sure using the pressure gaugeand air pressure regulator knob[6].
• If necessary, check and adjustalso the inlet air pressure byadjusting the external compres-sor.
LIMITATIONS
Do not exceed output current and duty cycle rating ofmachine. Do not use the TOMAHAWK™ 375 AIR forpipe thawing.
Continuous cutting with the internal compressor canonly be performed for approximately 4 minutes. Thecompressor has an internal thermostat to protect itfrom over heating.
If the arc turns off while cutting using low input volt-age, that is below 208V, lower the air pressure byadjusting the regulator knob.
B-5OPERATIONB-5
5. Internal / External Air selection: This switchselects the air supply. With the Internal Compressorposition selected, the machine operates through thebuilt-in compressor. With the External Air positionselected, the internal compressor is completely dis-abled and the machine operates through an exter-nal air supply hose connected to the proper air inletconnection located on the back of the machine.
If operating with External Air, be sure to select theExternal Air switch position in order to completelydisable the built-in compressor. Otherwise thecompressor may be damaged by the possibility ofgreater external air pressure.------------------------------------------------------------------------
6. Air Pressure Gauge and Regulator Knob: TheAir Pressure Gauge indicator is provided with twoarrows: one white and one blue:
• Internal Air mode (internal compressor): the whitearrow indicates the normal pressure that the inter-nal compressor can reach. This pressure set pointis fixed and cannot be adjusted.
• External Air mode (air supplied from an externalcompressor): use the blue arrow to set the correctair pressure (to set the correct pressure, turn theoutput knob into the blue Purge zone).
Items 7 thru 10 on the back of the TOMAHAWK™375 AIR (See Figure B.3)
7. Fan: Provides machine cooling. When the machineis switched ON, the fan runs continuously.
8. Power Switch: Turns ON / OFF the input power tothe machine.
9. Input cable: Connects unit to the input power.
10. Air Inlet: External Air operating mode only.Compressed Air Connection.
Clean, dry air must be supplied to the machine. Apressure setting above 110 PSI (7.5 bar) coulddamage the torch. Failure to observe these pre-cautions could result in excessive operating tem-peratures or damage to the torch.------------------------------------------------------------------------
CUTTING PROCESS
When preparing to cut, position the machine as closeto the work as possible. Make sure to have all materi-als needed to complete the job and have taken allsafety precautions. It is important to follow these oper-ating steps each time the machine is used.
Turn the machine's ON/OFF POWER SWITCH to theOFF position.
• Select the air supply using AIR select switch.
• Connect the air supply to the machine, if usingexternal air supply mode.
• Turn the main power on and the machine powerswitch to the ON position.- The fan will start.- The pre-charge circuit will operate for 3 seconds,
then the green "Power" LED will illuminate.
TOMAHAWK™ 375 AIR
WARNING
WARNING
10 98 7
FIGURE B.3
Direction of Travel
5 - 15
1/16”
10 - 20 Arc Lag
Leading Angle
• Use a 5° - 15° leading angle in the direction of the cut.
• Finish the cut to be made and release the trigger.
• When the trigger is released, the arc will stop.
- The gas will continue to flow for 15 seconds ofpostflow. If the trigger is activated within this timeperiod, the pilot arc will immediately restart.
• If the dross is difficult to remove, reduce the cuttingspeed. High speed dross is more difficult to removethan low speed dross.
• Clean spatter and scale from the nozzle frequently.
B-6OPERATIONB-6
TOMAHAWK™ 375 AIR
• Attach the work lead clamp to the workpiece beforecutting.
• Set the output current control knob to maximumposition for higher cutting speed and less dross for-mation. Reduce the current, if desired to reduce thekerf (cut) width, heat affected zone, or travel speedas required.
Note: If the circuit breaker trips while cutting at high-er amperages - reduce the cutting amperageon the unit, or provide an input circuit withhigher current capacity.
• Rotate the output knob into the purge zone to checkor set the gas pressure. Pull the pressure regulatorcap out and turn it to set the pressure.- Adjust the gas regulator for 75-80 PSI (0.50-0.55
MPa).- Turn the output knob out of the purge zone. - The gas will immediately turn off. The pressure
gage may show an increase in pressure after theair turns off but this is normal. Do NOT reset thepressure while the air is NOT flowing.
• When ready to cut, place the torch near the work,make certain all safety precautions have been takenand pull the trigger. - The air will flow for a preflow time of 2 seconds
and the pilot arc will start. (Exceptions: the firsttime that the trigger is pulled after the machine isturned on, or after a thermal trip out, initial triggerwill be ignored. This is a safety feature to preventthe pilot arc from firing unexpectedly or if thetorch trigger is inadvertently pressed. The otherexception is if the machine is in postflow, thenthe preflow time is skipped and the pilot arc willstart immediately.)
- The pilot arc will run for 3.0 seconds and shut offunless the arc is brought in contact with the workand the arc is transferred. Avoid excessive pilotarc time by transferring the arc to the workpiecequickly. This will extend consumable life.
- When the arc is brought within 1/8” - 1/4" fromthe work piece: the arc will transfer, the currentwill ramp to the setting on the control panel, andthe cut can last indefinitely (or until the dutycycle of the TOMAHAWK™ 375 AIR is exceed-ed).
ELECTRIC SHOCK CAN KILL. • Turn off machine at the disconnect
switch on the rear of the machinebefore tightening, cleaning orreplacing consumables.
• Pierce the work piece by slowly lowering the torchonto the metal at a 300 angle away from the opera-tor. This will blow the dross away from the torchtip. Slowly rotate the torch to vertical position asthe arc becomes deeper.
• Keep moving while cutting. Cut at a steady speedwithout pausing. Maintain the cutting speed so thatthe arc lag is 10° to 20° behind the travel direction.
When properly used, plasma arc cutting is a very eco-nomical process. Improper use will result in a veryhigh operating cost.
General - In All Cases
• Follow safety precautions as printed throughout thisoperating manual and on the machine.
• If piercing is required, slowly lower the torch at anangle of about 30° to blow the dross away fromthe torch tip and slowly rotate the torch to a ver-tical position as the arc becomes deeper. Thisprocess will blow a lot of molten metal anddross. Be careful! Blow the dross away fromthe torch, the operator and any flammableobjects.
• The nozzle should not be dragged on the metalsurface. A drag spacer is provided to maintain aconsistant touch height. Refer to Touch PartsConfigurations in this Section.
• Where possible, start the cut from the edge of thework piece.
• Keep moving! A steady speed is necessary. Do notpause.
Torch Standoff
DRAG thru 1/16"Standoff
1/16” Standoff
B-7OPERATIONB-7
TORCH• During operation, if the Red and Yellow LEDʼs light
together:
• Check the assembly of the torch consumables. Ifthey are not properly in place, the machine will notstart. Make sure that the shield cup is handtight. Do not use pliers or over tighten.
• Check the conditions of the inside of the nozzle. Ifdebris has collected, rub the electrode on the insidebottom of the nozzle to remove any oxide layer thatmay have built up. Refer to "Suggestions for ExtraUtility from the TOMAHAWK™ 375 AIR system".
• Check the condition of the electrode. If the end hasa crater-like appearance, replace it along with thenozzle. The maximum wear depth of the electrodeis approximately .062”. A green and erratic arc willindicate definite electrode failure and the electrodeshould be replaced immediately.
• Replace the nozzle when the orifice exit is erodedaway or oval shaped.
• After the problem is found, or if there is nothingapparently wrong, reset the machine by turning thepower switch OFF and then ON again. (It is possi-ble for electrical noise to trip the safety circuit onrare occasions. This should not be a regular occur-rence.)
• If the machine does not reset or continues to trip,consult the Troubleshooting Section.
• Use the proper cutting procedures referred to inProcedure Recommendations.
PILOT ARC DISCUSSION
The TOMAHAWK™ 375 AIR has a smooth, continu-ous pilot arc. The pilot arc is only a means of transfer-ring the arc to the workpiece for cutting. Repeatedpilot arc starts, in rapid succession, is not recom-mended as these starts will generally reduce consum-able life. Occasionally, the pilot arc may sputter orstart intermittently. This is aggravated when the con-sumables are worn or the air pressure is too high.Always keep in mind that the pilot arc is designed totransfer the arc to the workpiece and not for numerousstarts without cutting.
The TOMAHAWK™ 375 AIR does not utilize high fre-quency starting. When the pilot arc is started, a slightimpulse will be felt in the torch handle. This occur-rence is normal and is the mechanism which starts theplasma arc. This impulse can also be used to helptroubleshoot a "no start" condition.
TOMAHAWK™ 375 AIR
B-8OPERATIONB-8
Suggestions for Extra Utility from theTOMAHAWK™ 375 AIR System:
1. Occasionally an oxide layer may form over the tipof the electrode, creating an insulating barrierbetween the electrode and nozzle. This will resultin the tripping of the TOMAHAWK™ 375 AIR'ssafety circuit. When this happens turn the poweroff, remove the nozzle and electrode and use theelectrode to rub against the inside bottom surfaceof the nozzle. This will help remove any oxidebuildup. Replace the nozzle, turn on the power andcontinue cutting. If the safety circuit continues totrip after cleaning the consumables, then replacethem with a new set. Do not continue to try andcut with excessively worn consumables as this cancause damage to the torch head and will degradecut quality. Do not allow torch cable or body tocontact hot surface.
2. To improve consumable life, here are some sug-gestions that may be useful:
• Make sure the air supply to the TOMAHAWK™375 AIR is clean and free of oil. Use severalextra in line filters if necessary.
• Minimize dross buildup on the nozzle tip bystarting 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° fromthe plane perpendicular to the work piece,transfer the arc, then bring the torch perpendic-ular to the work and begin parallel movement.
• Reduce the number of pilot arc starts withouttransferring to the work.
• Reduce the pilot arc time before transferring tothe work.
TOMAHAWK™ 375 AIR
ELECTRIC SHOCK CAN KILL. • Turn off machine at the disconnect
switch on the rear of the machinebefore tightening, cleaning or replacingconsumables.
• Set air pressure to recommended setting. Ahigher or lower pressure will cause turbulencein the plasma arc, eroding the orifice of thenozzle tip.
• Use only Lincoln consumable parts. Theseparts are patented and using any other replace-ment consumables may cause damage to thetorch or reduce cut quality.
B-9OPERATIONB-9
TOMAHAWK™ 375 AIR
TORCH PART CONFIGURATIONS
The Tomahawk™ 375 Air uses a standard cuttingsetup as described below.
Standard Cutting Setup:In the Standard Cutting configuration the nozzle isdesigned not to touch the work piece. The advantageof this cutting method is good visibility of the arc.However it requires a steady hand to avoid touchingthe nozzle to the work piece which will cause prema-ture nozzle wear and a jagged cut. An optional dragspacer can be attached to the retaining cap to main-tain a consistent arc height.
Refer to the torch parts decal located on your machineor the parts pages at the back of this manual for thespecific part numbers required for each of thesesetups.
ALWAYS USE GENUINE LINCOLN ELECTRICELECTRODES, NOZZLES, AND EXPENDABLEPARTS FOR THE BEST CUTTING PERFOR-MANCE.
www.lincolnelectric.com
C-1ACCESSORIESC-1
TOMAHAWK™ 375 AIR
GENERAL OPTIONS /ACCESSORIES
The following options/accessories are available foryour Tomahawk Plasma cutter from your local LincolnDistributor.
K2377-1 - Small Canvas CoverProtect your machine when not in use. Made fromattractive red canvas that is flame retardant, mildewresistant and water repellent. It includes a convenientside pocket to hold the plasma torch.
K2886-1 - Plasma Circle Cutting Kit (Tomahawk) –For cutting circles from 3” to 33” in diameter (77mm to838mm).
TORCHES
The following replacement torch is available:
K2846-1 LC25 Handheld Plasma Torch 10' (3m)
EXPENDABLE PARTS
Refer to the torch parts decal located on your machineor the parts pages at the back of this manual for thespecific part numbers required for each of the avail-able setups.
D-1MAINTENANCED-1
TOMAHAWK™ 375 AIR
PERIODIC MAINTENANCE
Change consumables as required.
THERMAL PROTECTION
Thermal Detection Devices protect the machine fromexcessive operating temperatures. Excessive temper-atures may be caused by a lack of cooling air or oper-ating the machine beyond the duty cycle and outputrating. If excessive operating temperatures shouldoccur, the yellow thermal LED will light and theDetection Devices will prevent output voltage or cur-rent.
These Detection Devices are self-resetting once themachine cools sufficiently. If the thermostat shutdownwas caused by excessive output or duty cycle and thefan is operating normally, the Power Switch may beleft on and the reset should occur within a 15 minuteperiod. If the fan is not turning or the air intake louverswere obstructed, then the power must be switched offand the fan problem or air obstruction must be cor-rected.
A protection circuit is included to monitor the voltageacross filter capacitors. In the event that the capacitorvoltage is too high, the protection circuit will preventoutput.
ELECTRIC SHOCK CAN KILL.• Have an electrician install and ser-
vice this equipment.• Turn the input power off at the fuse
box before working on equipment.• Do not touch electrically hot parts.
1. Keep the cutting or gouging area and the areaaround the machine clean and free of combustiblematerials. No debris should be allowed to collectwhich could obstruct air flow to the machine.
2. Every 6 months or so, the machine should becleaned with a low pressure airstream. Keeping themachine clean will result in cooler operation andhigher reliability. Be sure to clean these areas:
- Printed circuit boards and heat sinks - Power switch
• When using a low pressure air stream, wearappropriate eye protection.
------------------------------------------------------------------------3. Examine the sheet metal case for dents or break-
age. Repair the case as required. Keep the case ingood condition to insure that high voltage parts areprotected and correct spacings are maintained. Allexternal sheet metal screws must be in place toinsure case strength and electrical ground continu-ity.
4. Inspect the cable periodically for any slits or punc-ture marks in the cable jacket. Replace if neces-sary. Check to make sure that nothing is crushingthe cable and blocking the flow of air through theair tube inside. Also, check for kinks in the cableperiodically and relieve any so as not to restrict theflow of air to the torch.
5. Regularly clean the compressor air inlet filter.
WARNING
ELECTRIC SHOCK CAN KILL. • Turn off machine at the disconnect
switch on the rear of the machinebefore tightening, cleaning orreplacing consumables.
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
This Troubleshooting Guide is provided tohelp you locate and repair possible machinemalfunctions. Simply follow the three-stepprocedure listed below.
Step 1. LOCATE PROBLEM (SYMPTOM).Look under the column labeled “PROBLEM(SYMPTOMS)”. This column describespossible symptoms that the machine mayexhibit. Find the listing that best describesthe symptom that the machine is exhibiting.
Step 2. POSSIBLE CAUSE.The second column labeled “POSSIBLECAUSE” lists the obvious external possibili-ties that may contribute to the machinesymptom.
Step 3. RECOMMENDED COURSE OFACTIONThis column provides a course of action forthe Possible Cause, generally it states tocontact you local Lincoln Authorized FieldService Facility.
If you do not understand or are unable toperform the Recommended Course ofAction safely, contact you local LincolnAuthorized Field Service Facility.
HOW TO USE TROUBLESHOOTING GUIDE
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 andmachine operator and will invalidate your factory warranty. For your safety and to avoidElectrical Shock, please observe all safety notes and precautions detailed throughout this manual.__________________________________________________________________________
WARNING
ELECTRIC SHOCK CAN KILL. • Turn off machine at the disconnect
switch on the rear of the machine andremove main power supply connec-tions before doing any troubleshooting.
Observe all Safety Guidelines detailed throughout this manual
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
PROBLEMS(SYMPTOMS)
POSSIBLE CAUSE
RECOMMENDEDCOURSE OF ACTION
Input circuit breaker trips repeatedly.
No Status indicators light and the fandoes not operate 5 seconds after thepower switch is turned on.
No Status indicators light 5 secondsafter the power switch is turned on,but the fan operates.
The Thermal LED does not go out.
1. This may be normal. If output isset to maximum a 20 amp circuit isrequired. See TechnicalSpecification page.
2. Install a larger input circuit or turnthe output control to a loweramperage.
1. Check the input power to be sureit is on.
2. Check the power line fuses orbreakers and machine connection.
3. Disconnect input power atfuse/breaker panel and check lineswitch continuity. Replace lineswitch if bad.
1. Possible faulty Inverter Board.
2. Possible faulty Control Board.
1. Check consumables - Thermaland output LEDʼs light when anunsafe condition exists at thetorch.
2. Possible faulty Inverter board.
3. Possible faulty Control Board
If all recommended possible areas ofmisadjustment have been checkedand the problem persists, Contactyour local Lincoln AuthorizedField Service Facility.
E-4TROUBLESHOOTINGE-4
TOMAHAWK™ 375 AIR
Observe all Safety Guidelines detailed throughout this manual
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
PROBLEMS(SYMPTOMS)
POSSIBLE CAUSE
RECOMMENDEDCOURSE OF ACTION
The TOMAHAWK™ 375 AIR powersup properly but there is no responsewhen the trigger is pulled and onlythe POWER LED is lit.
1. Turn the output knob to purgezone on the front of the TOMA-HAWK™ 375 AIR. If air does notflow, then:
• The main gas solenoid assem-bly/pressure sensor may befaulty. Check or replace.
• Possible faulty Inverter board.
2. Remove the handles (or barrel) ofthe torch and examine all the con-nections.
3. Check for proper trigger switchoperation. Replace the triggerswitch or torch cable if defective.
4. Possible faulty Inverter board.
5. Possible faulty Control board.
If all recommended possible areas ofmisadjustment have been checkedand the problem persists, Contactyour local Lincoln AuthorizedField Service Facility.
E-5TROUBLESHOOTINGE-5
TOMAHAWK™ 375 AIR
Observe all Safety Guidelines detailed throughout this manual
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
PROBLEMS(SYMPTOMS)
POSSIBLE CAUSE
RECOMMENDEDCOURSE OF ACTION
When the trigger is pulled air beginsto flow, but there is no pilot arc afterat least 3 seconds.
The air begins to flow and there is avery brief arc that snaps out consis-tently with repeated trigger pulls.
The arc starts but sputters badly.
1. Check the torch consumables to besure they are not dirty or greasy,and are in good shape. Replacethe consumables if necessary.
2. Make sure the air pressure is setcorrectly.
3. Make sure there are no kinks orrestrictions for air flow in the torchcable. Replace cable as needed.
4. If a slight thump cannot be felt inthe torch when the trigger ispulled, check for loose connectionin the torch head.
5. Possible faulty Inverter board.
1. Check the torch consumables tobe sure they are in tight, not dirtyor greasy and in good shape.Replace if necessary.
2. Make sure the air pressure is setcorrectly.
3. Possible faulty in Inverter board.
1. Check the torch consumables tobe sure they are in tight, not dirtyor greasy and in good shape.Replace if necessary.
2. Check air supply for oil or a greatdeal of water. If there is oil or agreat deal of water, the air mustbe fi l tered or the machineswitched to nitrogen or bottled air.
3. Make sure the air pressure is setcorrectly.
If all recommended possible areas ofmisadjustment have been checkedand the problem persists, Contactyour local Lincoln AuthorizedField Service Facility.
E-6TROUBLESHOOTINGE-6
TOMAHAWK™ 375 AIR
Observe all Safety Guidelines detailed throughout this manual
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
PROBLEMS(SYMPTOMS)
POSSIBLE CAUSE
RECOMMENDEDCOURSE OF ACTION
Pilot arc starts but will not transferwhen brought near work.
Pilot arc initiates but turns off beforetransferring to work. Cutting arcappears to turn off while cutting.
1. Check work lead connection forclean, secure connection.
2. Plasma will only cut conductivematerial. Do not attempt to cutfiberglass, plastic, rubber, PVC or any other non-conductive material.
3. Make sure work piece is clean anddry. Remove any scale, rust ordross.
4. Possible faulty Inverter board.
5. Check all connections to Controlboard.
1. Input voltage is below 208V.
2. Air pressure is set too high.
If all recommended possible areas ofmisadjustment have been checkedand the problem persists, Contactyour local Lincoln AuthorizedField Service Facility.
Lower air pressure by turning regula-tor knob. Pressure may require beingset lower than blue arrow indicator.
SYMPTOM
When trigger is pulled Red output LED isBlinking or steady with no air flow.
The Green, Red and Yellow LEDʼs are litand steady. Indicates safety circuit is open.
The Thermal LED is lit.
In internal compressor Mode: The cuttingarc turns off while cutting and the compres-sor turns off. All LEDʼs appear normal. Fanis operating.
When the trigger is pulled the Red andYellow LEDʼs are blinking together and theGreen light is on.
When the trigger is pulled the Red LED is lit,air flows and no pilot arc occurs.
The Red and Yellow LEDʼs are blinkingalternately.
When the trigger is pulled no air flows, RedLED is lit, no pilot arc. Then LED goes out.
E-7TROUBLESHOOTINGE-7
TOMAHAWK™ 375 AIR
Observe all Safety Guidelines detailed throughout this manual
STATUS BOARD INDICATORS
CHECK
1. Make sure there is at least 80 psi connected to the gas connec-tion at the back of the machine.
2. Turn the output knob to the purge zone and set the regulator tothe correct pressure. The pressure may increase when air stopsflowing but this is normal. Do not reset the pressure while the airis OFF.
3. Possible faulty Pressure Switch.
4. Possible faulty Inverter board.
Turn the power OFF and then ON. If torch and consumables areproperly installed and they are the correct parts, the Red andYellow LEDʼs should turn off. Normal cutting or gouging canresume.
1. The machine's thermostat has tripped due to exceeded dutycycle limits. Do NOT turn the power off. Allow the machine tocool for 15 - 30 minutes and the thermostat will reset itself.
2. The machine's air louvers or fans are obstructed such that aircannot flow to properly cool the machine. Remove any foreignmaterial that may block air flow. Blow the machine out with aclean, dry air stream.
3. The input voltage is not within ±10% of rated values.
4. Possible faulty Inverter board.
1. The compressor has over heated and tripped itʼs internal thermo-stat. Do NOT turn the power off. Allow the machine to cool for 15- 30 minutes and the thermostat will reset itself.
1. Check that nozzle and swirl ring are properly installed and theyare the correct parts. Note: Swirl ring can only go in one way.
2. Input voltage is too low and /or air pressure is set too high.Lower air pressure.
1. Check that swirl ring is properly installed. Note: Swirl ring can only go in one way.
1. The torch safety circuit has been opened, when reconnected thiscondition should correctly reset automatically.
1. Check that the pressure gauge shows pressure.Air supply may not be connected or properly installed.
F-1WIRING DIAGRAMF-1
TOMAHAWK™ 375 AIR
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WARNING
AVISO DEPRECAUCION
ATTENTION
WARNUNG
ATENÇÃO
Spanish
French
German
Portuguese
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THECONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DEESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SUSUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENTET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTREEMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRO-DENEINSATZ DES HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERSSIND EBENFALLS ZU BEACHTEN.
• Do not touch electrically live parts orelectrode with skin or wet clothing.
• Insulate yourself from work andground.
• No toque las partes o los electrodosbajo 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 contactavec des pièces sous tension.
• Isolez-vous du travail et de la terre.
• Berühren Sie keine stromführendenTeile oder Elektroden mit IhremKörper oder feuchter Kleidung!
• Isolieren Sie sich von denElektroden und dem Erdboden!
• Não toque partes elétricas e electro-dos com a pele ou roupa molhada.
• Isole-se da peça e terra.
• Keep flammable materials away.
• Mantenga el material combustiblefuera del área de trabajo.
• Gardez à l’écart de tout matérielinflammable.
• Entfernen Sie brennbarres Material!
• Mantenha inflamáveis bem guarda-dos.
• Wear eye, ear and body protection.
• Protéjase los ojos, los oídos y elcuerpo.
• Protégez vos yeux, vos oreilles etvotre corps.
• Tragen Sie Augen-, Ohren- und Kör-perschutz!
• Use proteção para a vista, ouvido ecorpo.
WARNING
AVISO DEPRECAUCION
ATTENTION
WARNUNG
ATENÇÃO
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LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTESDE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
• Keep your head out of fumes.• Use ventilation or exhaust to
remove fumes from breathing zone.
• Los humos fuera de la zona de res-piración.
• Mantenga la cabeza fuera de loshumos. Utilice ventilación oaspiración para gases.
• Gardez la tête à l’écart des fumées.• Utilisez un ventilateur ou un aspira-
teur pour ôter les fumées des zonesde travail.
• Vermeiden Sie das Einatmen vonSchweibrauch!
• Sorgen Sie für gute Be- undEntlüftung 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 máquinaantes de iniciar cualquier servicio.
• Débranchez le courant avant l’entre-tien.
• Strom vor Wartungsarbeitenabschalten! (Netzstrom völlig öffnen;Maschine anhalten!)
• Não opere com as tampas removidas.• Desligue a corrente antes de fazer
serviço.• Não toque as partes elétricas nuas.
• Do not operate with panel open orguards off.
• No operar con panel abierto oguardas quitadas.
• N’opérez pas avec les panneauxouverts ou avec les dispositifs deprotection enlevés.
• Anlage nie ohne Schutzgehäuseoder Innenschutzverkleidung inBetrieb setzen!
• Mantenha-se afastado das partesmoventes.
• Não opere com os paineis abertosou guardas removidas.
• Sales and Service through Subsidiaries and Distributors Worldwide •
