im10020 tomahawk 625 january 2013 - lincoln electric...may 16, 2018 · 2.d.2. never coil the...

TTOMAHAWK ™ 625

OPERATORʼS MANUAL

IM10020January 2013

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: 11580

• 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 Leader in Welding and Cutting Products •

Copyright © Lincoln Global Inc.

THANK YOU FOR SELECTING A QUALITY PRODUCT BY LINCOLN ELEC TRIC.

PLEASE EXAMINE CARTON AND EQUIPMENT FORDAMAGE IMMEDIATELY

When this equipment is shipped, title passes to the purchaserupon receipt by the carrier. Consequently, claims for materialdamaged in shipment must be made by the purchaser against thetransportation company at the time the shipment is received.

SAFETY DEPENDS ON YOU

Lincoln arc welding and cutting equipment is designed and builtwith safety in mind. However, your overall safety can be increasedby proper installation ... and thoughtful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETYPRECAUTIONS CONTAINED THROUGHOUT. And, most importantly,think before you act and be careful.

This statement appears where the information must be followedexactly to avoid serious personal injury or loss of life.

This statement appears where the information must be followedto avoid minor personal injury or damage to this equipment.

KEEP YOUR HEAD OUT OF THE FUMES.

DON’T get too close to the arc.Use corrective lenses if necessaryto stay a reasonable distanceaway from the arc.

READ and obey the Safety DataSheet (SDS) and the warning labelthat appears on all containers ofwelding materials.

USE ENOUGH VENTILATION orexhaust at the arc, or both, tokeep the fumes and gases from your breathing zone and the general area.

IN A LARGE ROOM OR OUTDOORS, natural ventilation may beadequate if you keep your head out of the fumes (See below).

USE NATURAL DRAFTS or fans to keep the fumes away from your face.

If you de velop unusual symptoms, see your supervisor. Perhaps the welding atmosphere and ventilation system should be checked.

WEAR CORRECT EYE, EAR & BODY PROTECTION

PROTECT your eyes and face with welding helmetproperly fitted and with proper grade of filter plate(See ANSI Z49.1).

PROTECT your body from welding spatter and arcflash with protective clothing including woolenclothing, flame-proof apron and gloves, leatherleggings, and high boots.

PROTECT others from splatter, flash, and glarewith protective screens or barriers.

IN SOME AREAS, protection from noise may be appropriate.BE SURE protective equipment is in good condition.Also, wear safety glasses in work areaAT ALL TIMES.

SPECIAL SITUATIONSDO NOT WELD OR CUT containers or materials which previouslyhad been in contact with hazardous substances unless they areproperly cleaned. This is extremely dangerous.

DO NOT WELD OR CUT painted or plated parts unless specialprecautions with ventilation have been taken. They can releasehighly toxic fumes or gases.

Additional precautionary measuresPROTECT compressed gas cylinders from excessive heat,mechanical shocks, and arcs; fasten cylinders so they cannot fall.

BE SURE cylinders are never grounded or part of an electrical circuit.

REMOVE all potential fire hazards from welding area.ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FORIMMEDIATE USE AND KNOW HOW TO USE IT.

WARNING

CAUTION

Safety 01 of 04 - 5/16/2018

SECTION A:WARNINGS

CALIFORNIA PROPOSITION 65 WARNINGSWARNING: Breathing diesel engine exhaustexposes you to chemicals known to the Stateof California to cause cancer and birth defects,

or other reproductive harm.• Always start and operate the engine in a

well-ventilated area.• If in an exposed area, vent the exhaust to the outside.• Do not modify or tamper with the exhaust system. • Do not idle the engine except as necessary.For more information go to www.P65 warnings.ca.gov/diesel

WARNING: This product, when used for welding orcutting, produces fumes or gases which containchemicals known to the State of California to causebirth defects and, in some cases, cancer. (CaliforniaHealth & Safety Code § 25249.5 et seq.)

WARNING: Cancer and Reproductive Harmwww.P65warnings.ca.gov

ARC WELDING CAN BE HAZARDOUS. PROTECTYOURSELF AND OTHERS FROM POSSIBLE SERIOUSINJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITHTHEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. Foradditional safety information, it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION,MAINTENANCE AND REPAIR PROCEDURES AREPERFORMED ONLY BY QUALIFIED INDIVIDUALS.

FOR ENGINE POWEREDEQUIPMENT.

1.a. Turn the engine off before troubleshootingand maintenance work unless themaintenance work requires it to be running.

1.b. Operate engines in open, well-ventilated areas or vent the engineexhaust fumes outdoors.

1.c. Do not add the fuel near an open flame weldingarc or when the engine is running. Stop theengine and allow it to cool before refueling toprevent spilled fuel from vaporizing on contact

with hot engine parts and igniting. Do not spill fuel when fillingtank. If fuel is spilled, wipe it up and do not start engine untilfumes have been eliminated.

1.d. Keep all equipment safety guards, covers and devices in position and in good repair.Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating orrepairing equipment.

1.e. In some cases it may be necessary to remove safety guards toperform required maintenance. Remove guards only whennecessary and replace them when the maintenance requiringtheir removal is complete. Always use the greatest care whenworking near moving parts.

1.f. Do not put your hands near the engine fan. Do not attempt tooverride the governor or idler by pushing on the throttle controlrods while the engine is running.

1.g. To prevent accidentally starting gasoline engines while turningthe engine or welding generator during maintenance work,disconnect the spark plug wires, distributor cap or magneto wireas appropriate.

1.h. To avoid scalding, do not remove the radiatorpressure cap when the engine is hot.

ELECTRIC ANDMAGNETIC FIELDS MAYBE DANGEROUS

2.a. Electric current flowing through any conductorcauses localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines

2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physicianbefore welding.

2.c. Exposure to EMF fields in welding may have other health effectswhich are now not known.

2.d. All welders should use the following procedures in order tominimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Securethem with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and workcables. If the electrode cable is on your right side, thework cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as pos-sible to the area being welded.

2.d.5. Do not work next to welding power source.

SAFETY

Safety 02 of 04 - 5/16/2018

ELECTRIC SHOCK CAN KILL.

3.a. The electrode and work (or ground) circuits areelectrically “hot” when the welder is on. Donot touch these “hot” parts with your bare skin or wet clothing.Wear dry, hole-free gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation.Make certain the insulation is large enough to cover your full areaof physical contact with work and ground.

In addition to the normal safety precautions, ifwelding must be performed under electricallyhazardous conditions (in damp locations or whilewearing wet clothing; on metal structures such asfloors, gratings or scaffolds; when in crampedpositions such as sitting, kneeling or lying, if thereis a high risk of unavoidable or accidental contactwith the workpiece or ground) use the followingequipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,electrode reel, welding head, nozzle or semiautomatic weldinggun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electricalconnection with the metal being welded. The connection shouldbe as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical (earth)ground.

3.f. Maintain the electrode holder, work clamp, welding cable andwelding machine in good, safe operating condition. Replacedamaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts of electrodeholders connected to two welders because voltage between thetwo can be the total of the open circuit voltage of bothwelders.

3.i. When working above floor level, use a safety belt to protectyourself from a fall should you get a shock.

3.j. Also see It ems 6.c. and 8.

ARC RAYS CAN BURN.

4.a. Use a shield with the proper filter and cover plates to protect youreyes from sparks and the rays of the arc when welding orobserving open arc welding. Headshield and filter lens shouldconform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistant materialto protect your skin and that of your helpers from the arc rays.

4.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.

FUMES AND GASESCAN BE DANGEROUS.

5.a. Welding may produce fumes and gaseshazardous to health. Avoid breathing thesefumes and gases. When welding, keep your head out of the fume.Use enough ventilation and/or exhaust at the arc to keep fumesand gases away from the breathing zone. When weldinghardfacing (see instructions on container or SDS)or on lead or cadmium plated steel and othermetals or coatings which produce highly toxicfumes, keep exposure as low as possible andwithin applicable OSHA PEL and ACGIH TLV limitsusing local exhaust or mechanical ventilationunless exposure assessments indicate otherwise.In confined spaces or in some circumstances,outdoors, a respirator may also be required.Additional precautions are also required whenwelding on galvanized steel.

5. b. The operation of welding fume control equipment is affected byvarious factors including proper use and positioning of theequipment, maintenance of the equipment and the specificwelding procedure and application involved. Worker exposurelevel should be checked upon installation and periodicallythereafter to be certain it is within applicable OSHA PEL andACGIH TLV limits.

5.c. Do not weld in locations near chlorinated hydrocarbon vaporscoming from degreasing, cleaning or spraying operations. Theheat and rays of the arc can react with solvent vapors to formphosgene, a highly toxic gas, and other irritating products.

5.d. Shielding gases used for arc welding can displace air and causeinjury or death. Always use enough ventilation, especially inconfined areas, to insure breathing air is safe.

5.e. Read and understand the manufacturer’s instructions for thisequipment and the consumables to be used, including theSafety Data Sheet (SDS) and follow your employer’s safetypractices. SDS forms are available from your weldingdistributor or from the manufacturer.

5.f. Also see item 1.b.

SAFETY

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WELDING AND CUTTINGSPARKS CAN CAUSEFIRE OR EXPLOSION.

6.a. Remove fire hazards from the welding area. Ifthis is not possible, cover them to prevent the welding sparksfrom starting a fire. Remember that welding sparks and hotmaterials from welding can easily go through small cracks andopenings to adjacent areas. Avoid welding near hydraulic lines.Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site, specialprecautions should be used to prevent hazardous situations.Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1)and the operating information for the equipment being used.

6.c. When not welding, make certain no part of the electrode circuit istouching the work or ground. Accidental contact can causeoverheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until theproper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside.They can cause an explosion even though they have been“cleaned”. For information, purchase “Recommended SafePractices for the Preparation for Welding and Cutting ofContainers and Piping That Have Held Hazardous Substances”,AWS F4.1 from the American Welding Society (see address above).

6.e. Vent hollow castings or containers before heating, cutting orwelding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oil freeprotective garments such as leather gloves, heavy shirt, cufflesstrousers, high shoes and a cap over your hair. Wear ear plugswhen welding out of position or in confined places. Always wearsafety glasses with side shields when in a welding area.

6.g. Connect the work cable to the work as close to the welding areaas practical. Work cables connected to the building framework orother locations away from the welding area increase thepossibility of the welding current passing through lifting chains,crane cables or other alternate circuits. This can create firehazards or overheat lifting chains or cables until they fail.

6.h. Also see item 1.c.

6.I. Read and follow NFPA 51B “Standard for Fire Prevention DuringWelding, Cutting and Other Hot Work”, available from NFPA, 1Batterymarch Park, PO box 9101, Quincy, MA 022690-9101.

6.j. Do not use a welding power source for pipe thawing.

CYLINDER MAY EXPLODE IFDAMAGED.

7.a. Use only compressed gas cylinders containingthe correct shielding gas for the process usedand properly operating regulators designed forthe gas and pressure used. All hoses, fittings,etc. should be suitable for the application andmaintained in good condition.

7.b. Always keep cylinders in an upright position securely chained toan undercarriage or fixed support.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjectedto physical damage.

• A safe distance from arc welding or cutting operationsand any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any otherelectrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outletwhen opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand tightexcept when the cylinder is in use or connected for use.

7.g. Read and follow the instructions on compressed gas cylinders,associated equipment, and CGA publication P-l, “Precautions forSafe Handling of Compressed Gases in Cylinders,” available fromthe Compressed Gas Association, 14501 George Carter WayChantilly, VA 20151.

FOR ELECTRICALLYPOWERED EQUIPMENT.

8.a. Turn off input power using the disconnectswitch at the fuse box before working on the equipment.

8.b. Install equipment in accordance with the U.S. National ElectricalCode, all local codes and the manufacturer’s recommendations.

8.c. Ground the equipment in accordance with the U.S. NationalElectrical Code and the manufacturer’s recommendations.

Refer tohttp://www.lincolnelectric.com/safety

for additional safety information.

SAFETY

Safety 04 of 04 - 5/16/2018

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.

TABLE OF CONTENTSPage

Installation.......................................................................................................................Section ATechnical Specifications.......................................................................................................A-1Safety Precautions ...............................................................................................................A-2Select Proper Location .........................................................................................................A-2Stacking................................................................................................................................A-2Tilting....................................................................................................................................A-2High Frequency Interference Protection...............................................................................A-2Input Electrical Connections.................................................................................................A-2Gas Input Connections.........................................................................................................A-3Output Connections..............................................................................................................A-3

Torch .............................................................................................................................A-3________________________________________________________________________________

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-6Pilot Arc Discussion..............................................................................................................B-7Procedure Recommendations..............................................................................................B-7

General .........................................................................................................................B-7Suggestions for Extra Utility from the TOMAHAWK™ 625 System ..............................B-8

Torch Part Configuration.............................................................................................B-9, B-10________________________________________________________________________________

Accessories .....................................................................................................Section C________________________________________________________________________

Maintenance ....................................................................................................Section DSafety Precautions ................................................................................................D-1Routine Maintenance.............................................................................................D-1Periodic Maintenance............................................................................................D-1

________________________________________________________________________

Troubleshooting ..............................................................................................Section ESafety Precautions.................................................................................................E-1How to Use Troubleshooting Guide.......................................................................E-1Error Signals ..........................................................................................................E-2Troubleshooting Guide ...........................................................................E-3 Thru E-7

________________________________________________________________________

Wiring Diagrams ..............................................................................................Section FWiring Diagram ......................................................................................................F-1

________________________________________________________________________

Parts Lists ........................................................................................................AppendixTOMAHAWK™ 625................................................................................P-626 SeriesTorch.............................................................................................................P-210-W

________________________________________________________________________

vivi

A-1INSTALLATION A-1

WeightIncluding

Torch Cable

34.0 lbs.15.4 kg.

INPUT - SINGLE PHASE 50 / 60 HERTZ

RATED OUTPUT AT 40° C

OUTPUT

RECOMMEND INPUT WIRE AND FUSE SIZES

REQUIRED GAS FLOW RATE REQUIRED GAS INLET PRESSURE

PHYSICAL DIMENSIONS

TECHNICAL SPECIFICATIONS -TOMAHAWK™ 625

Standard Voltage

Duty Cycle100%60%35%

CurrentRange

10-40 Amps

AC Input Voltage

at50/60Hertz

230V-1Ø 208V-1Ø

Fuse(Super Lag)

Circuit Breaker(Delay Type)

30 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 AMPS24 A29 A40 A

VOLTAGE VOLTS89.6VDC91.8VDC96.0VDC

208V, 230V ±10% / 1 / 50 / 60Hz

70 PSI @ 125-200 SCFH( 5 Bar. @ 80±20 LITERS/MIN.)

80 to 110 PSI(6 Bar. to 7.5 Bar.)

40 A

Output Input Cord Plug Size

6-50P

TOMAHAWK™ 625

TEMPERATURE RANGESOPERATING TEMPERATURE RANGE

-10°C to +40°CSTORAGE TEMPERATURE RANGE

-10°C to +40°C

A-2INSTALLATION

TOMAHAWK™ 625

A-2

Read entire Installation Section before installing theTOMAHAWK™ 625.

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™ 625 Power Switch

OFF when connecting power cord to inputpower.

___________________________________________

SELECT PROPER LOCATION

Place the TOMAHAWK™ 625 where clean cool aircan freely circulate in and out of 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™ 625 when using external airsupply. Oil in the air is a severe problem and must beavoided. 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™ 625 cannot be stacked.

TILTING

The TOMAHAWK™ 625 must be placed on a stable,level surface so it will not topple over.

HIGH FREQUENCY INTERFERENCEPROTECTION

The TOMAHAWK™ 625 employs a touch start mech-anism for arc initiation which eliminates high frequen-cy 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™ 625 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™ 625 or possibly even damage to the controlsystem or power supply components.

INPUT ELECTRICAL CONNECTIONS

The TOMAHAWK™ 625 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™ 625 should be connected onlyby 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™ 625 can be operated on enginedriven generators as long as the 230 volt auxiliarymeets the following conditions:

• The AC waveform peak voltage is below 400 volts.• The AC waveform frequency is between 45 and 65

Hz.• The RMS voltage of the AC waveform is always

greater than 208VAC.

WARNING

A-3INSTALLATION

TOMAHAWK™ 625

A-3

The following Lincoln engine drives meet these condi-tions when run in the high idle mode:Outback 185, Ranger 225, 250, 250LPG, 305G and305D engine drives. Vantage 300, 400, 500 and Air Vantage engine drives.

Operation of the TOMAHAWK™ 625 is not recom-mended on engine drives not conforming to theseconditions. Such combinations may overvoltage theTOMAHAWK™ 625 power source.

GAS INPUT CONNECTIONS(External Air Supply)

Supply the TOMAHAWK™ 625 with clean com-pressed air or nitrogen.

• Supply pressure must be between 80 psi and 110 psi.

• Flow rate should be approximately 125 - 200SCFH (80 ±20 L/min).

NOTE: Oil in the air supply to the TOMAHAWK™ 625can cause severe problems. Use only a cleanair 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™ 625.

• 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™ 625, the filter ele-ment 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™ 625 as specified in the Installation sectionof 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™ 625 regulator shouldnever exceed 110 psi.

• Install a hose between the nitrogen gas cylin-der regulator and the TOMAHAWK™ 625 gasinlet.

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

Torch

The TOMAHAWK™ 625 is sent from the factory witha cutting torch and work clamp included. The workclamp must be securely connected to the work piece.If the work piece is painted or extremely dirty it maybe necessary to expose the bare metal in order tomake a good electrical connection.

WARNING

B-1OPERATION

TOMAHAWK™ 625

B-1

SAFETY PRECAUTIONS DESCRIPTION

The TOMAHAWK™ 625 is a constant current, contin-uous control plasma cutting power source. It providessuperior and reliable starting characteristics, cuttingvisibility and arc stability. The control system has asafety mechanism to insure that the nozzle and elec-trode are in place before cutting or gouging. This isextremely important due to the high voltages involved.

The TOMAHAWK™ 625 comes standard with an airregulator and pressure gauge. The machine alsocomes with an input power cord, Hand-held torch witha 20' cable length. Consumables are included witheach TOMAHAWK™ 625 purchase so that cutting canbegin right out of the box. Consumables can also beordered as individual packages.

The TOMAHAWK™ 625 initiates the plasma arc witha simple, yet reliable, touch start mechanism. Thissystem eliminates many of the failure problems asso-ciated 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™ 625 design makes plasma cuttinguncomplicated. This list of design features and advan-tages will help you understand the machine's totalcapabilities so that you can get maximum use fromyour machine.

- Light weight and portable design for industrial use.

- Continuous control, 10 - 40 amps.

- Reliable touch start mechanism for plasma arc initi-ation.

- Rapid arc restrike for fast cutting of expanded metal.

- Input over voltage protection.

- Bright 3.0 second timed pilot arc.

- Purge section on output dial.

- Air regulator and pressure gage included.

- Internal water separator included.

- Parts-in-Place mechanism to detect proper installa-tion of consumables and torch.

- Preflow/Postflow timing. Preflow is eliminated if arcis re-initiated in Postflow.

- Thermostatic Protection.

- Solid state over-current protection.

- Unique electrode and nozzle design for optimumcooling and long life.

TOMAHAWK™ 625

B-3OPERATIONB-3

CUTTING CAPABILITY

The TOMAHAWK™ 625 is rated at 40 amps, at 35%duty cycle on a 10 minute basis. If the duty cycle isexceeded, a thermal protector will shut off the outputof the machine until it cools to the normal operatingtemperature.

Figure B.1 shows the cut capacity of the TOMA-HAWK™ 625 when cutting mild steel. (The graphplots cut thickness vs. torch travel speed with a torchstandoff of 0.15".)

TOMAHAWK™ 625

CONSUMABLE LIFE

The expected life for the TOMAHAWK™ 625's elec-trode under normal operating conditions is approxi-mately 1000 starts/cuts. An erosion of .060" is typicalfor end of electrode life, however, the electrode lifemay last longer. A green and erratic arc will indicatedefinite electrode failure and the electrode should bereplaced immediately.

It is recommended that consumables be replaced incomplete sets. (Example: Electrode and Nozzle). Thiswill maximize the performance of the TOMAHAWK™625 system.

Figure B.1

TOMAHAWK 625

Tomahawk 625 - Cut Capacity Chart

0

10

20

30

40

50

60

70

80

90

0.125 0.25 0.375 0.5 0.625 0.75

Metal Thickness (inches)

RE

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MM

EN

DE

D T

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TR

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SP

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IPM

)

CONTROLS AND SETTINGS(Figure B.2)

TOMAHAWK™ 625 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.

1MPa = 145 psiA

V A

10

40

25

TOMAHAWK6 2 5

www.lincolnelectric.com

1

2

3

4

5

B-4OPERATIONB-4

TOMAHAWK™ 625

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™ 625 for pipethawing.

If the arc turns off while cutting using low input volt-age, that is below 208V, lower the air pressure byadjusting the regulator knob.

When using with the Outback 180, gouging is not rec-ommended.

B-5OPERATIONB-5

5. Air Pressure Gauge and Regulator Knob: Allowsregulation and monitoring of the air pressure.

Items 6 thru 9 on the back of the TOMAHAWK™625 (See Figure B.3)

6. Fan: Provides machine cooling. When the machineis switched ON, the fan runs continuously.

7. Power Switch: Turns ON / OFF the input power tothe machine.

8. Input cable: Connects unit to the input power.

9. 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.

FIGURE B.3

Turn the machine's ON/OFF POWER SWITCH to theOFF position.

• Connect the air supply to the machine.

• 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.

• 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.

TOMAHAWK™ 625

WARNING

9 87 6

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.

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™ 625 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.

B-6OPERATIONB-6

TOMAHAWK™ 625

• When ready to cut, place the torch near the work,make certain all safety precautions have beentaken and 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™ 625 is exceeded).

• 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.

303000

VERVERTICAL ANGLETICAL ANGLEFOR CUTTINGFOR CUTTING

CUT

900

TORCH AT 300 ANGLETO PIERCE

ROTATE TO900 ANGLE TO CUT

ELECTRIC SHOCK CAN KILL. • Turn off machine at the disconnect

switch on the rear of the machinebefore tightening, cleaning orreplacing consumables.

----------------------------------------------------------------------------

WARNING

PROCEDURE RECOMMENDATIONS

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. Donot pause.

Torch Standoff

DRAG thru 1/16"�Standoff

1/16” Standoff

B-7OPERATIONB-7• Replace the nozzle when the orifice exit is eroded

away 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™ 625 has a smooth, continuouspilot arc. The pilot arc is only a means of transferringthe arc to the workpiece for cutting. Repeated pilot arcstarts, in rapid succession, is not recommended asthese starts will generally reduce consumable life.Occasionally, the pilot arc may sputter or start inter-mittently. This is aggravated when the consumablesare worn or the air pressure is too high. Always keepin mind that the pilot arc is designed to transfer the arcto the workpiece and not for numerous starts withoutcutting.

The TOMAHAWK™ 625 does not utilize high frequen-cy 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™ 625

B-8OPERATIONB-8

Suggestions for Extra Utility from theTOMAHAWK™ 625 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™ 625's safetycircuit. When this happens turn the power off,remove the nozzle and electrode and use the elec-trode to rub against the inside bottom surface ofthe 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™625 is clean and free of oil. Use several extra inline filters if necessary.

• Minimize dross buildup on the nozzle tip bystarting the cut from the edge of the plate whenpossible.

• 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™ 625


switch on the rear of the machinebefore tightening, cleaning or replacingconsumables.

----------------------------------------------------------------------------

WARNING

• 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-9TORCH PART CONFIGURATIONS

There are different torch configurations depending onthe cutting or gouging application.

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.

Contact Cutting Setup:Contact Cutting uses special expendable parts thatallow the torch to touch the work piece. The advan-tage of contact cutting is that the torch can touch thework piece, steadily dragging it across the surface.The disadvantage of contact cutting is the plasma arcis not as visible as with a standard torch set-up. Sincethis machine cuts at 40 amps or less it uses the directcontact torch configuration which allows a special noz-zle to come in contact with the work piece.

TOMAHAWK™ 625


B-10OPERATIONB-10Gouging Setup:If gouging metal and not cutting completely throughthe part is required, a special gouging nozzle is usedin conjunction with a gouge shield to protect the noz-zle from molten metal blow back.

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.

TOMAHAWK™ 625


C-1ACCESSORIESC-1

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 KitFor cutting circles from 3” to 33” in diameter (77mm to838mm).

TORCHES

The following replacement torch is available:

K2847-1 LC40 Handheld Plasma Torch 20' (6m)

EXPENDABLE PARTS

Refer to the torch parts decal located on your machineor the parts pages at the back of this manual for thespecific part numbers required for each of the avail-able setups.

TOMAHAWK™ 625

D-1MAINTENANCED-1

TOMAHAWK™ 625

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.

---------------------------------------------------------------------

ROUTINE MAINTENANCE

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.

WARNING


switch on the rear of the machinebefore tightening, cleaning orreplacing consumables.

----------------------------------------------------------------------------

WARNING

CAUTION

E-1TROUBLESHOOTINGE-1

TOMAHAWK™ 625

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


switch on the rear of the machine andremove main power supply connec-tions before doing any troubleshooting.

----------------------------------------------------------------------------

WARNING


TOMAHAWK™ 625

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1. This may be normal. If output isset to maximum a 30 amp circuitis required. 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.


3. Possible faulty Control Board.


TOMAHAWK™ 625

Observe all Safety Guidelines detailed throughout this manual


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.

If all recommended possible areas ofmisadjustment have been checkedand the problem persists, Contactyour local Lincoln AuthorizedField Service Facility.


TOMAHAWK™ 625



CAUTION

PROBLEMS(SYMPTOMS)

POSSIBLE CAUSE


The TOMAHAWK™ 625 powers upproperly 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™ 625. If air does not flow,then:

• The main gas solenoid assem-bly/pressure sensor may befaulty. Check or replace.

• Possible faulty Control 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.


5. Possible faulty Control board.



TOMAHAWK™ 625



CAUTION

PROBLEMS(SYMPTOMS)

POSSIBLE CAUSE


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.



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.




TOMAHAWK™ 625



CAUTION

PROBLEMS(SYMPTOMS)

POSSIBLE CAUSE


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 cleanand dry. Remove any scale, rustor dross.


5. Check all connections to ControlBoard.

1. Input voltage is below 208V.

2. Air pressure is set too high.


Lower air pressure by turning regula-tor knob. Pressure may requirebeing set lower than blue arrow indi-cator.


TOMAHAWK™ 625


STATUS BOARD INDICATORS

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.

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.

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.


1. 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.


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-1DIAGRAMSF-1

TOMAHAWK™ 625

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NOTES

TOMAHAWK™ 625

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

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

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 •

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 •

Table of ContentsInstallationTechnical SpecificationsSafety PrecautionsSelect Proper LocationStackingTiltingHigh Frequency Interference ProtectionInput Electrical ConnectionsGas Input ConnectionsOutput Connections

OperationSafety PrecautionsDescriptionPreheat Temperature for Plasma CuttingUser ResponsibilityDesign Features and AdvantagesCutting CapabilityConsumable LifeLimitationsControls and SettingsCutting ProcessPilot Arc DiscussionProcedure RecommendationsTorch Part Configurations

AccessoriesMaintenanceSafety PrecautionsRoutine MaintenancePeriodic Maintenance

TroubleshootingSafety PrecautionsHow to Use Troubleshooting GuideError SignalsTroubleshooting Guide

Wiring DiagramsWiring Diagram

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