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TOMAHAWK 1000
For use with machines having Code Number:

IM10026
August, 2011

11581

Safety Depends on You

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

IP23

OPERATORS MANUAL

Copyright Lincoln Global Inc.

World's Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEBSITE: www.lincolnelectric.com

SAFETY

WARNING

PLASMACUTTINGor GOUGING can be hazardous.

PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. 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 you purchase a copy of Safety in Welding & Cutting - ANSIStandard Z49.1from the American Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSAStandard W117.2.

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

1.a. The electrode and work (or ground) circuits are electrically hot when the power source is on. Do not touch these hot parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 1.b. When the power source is operating voltages in excess of 250 volts are produced. This creates the potential for serious electrical shock - potentially even fatal. 1.c. Insulate yourself from work and ground using dry insulation. When cutting or gouging in damp locations, on metal framework such as floors, gratings or scaffolds and when in positions such as sitting or lying, make certain the insulation is large enough to cover your full area of physical contact with work and ground. 1.d. Always be sure the work cable makes a good electrical connection with the metal being cut or gouged. The connection should be as close as possible to the area being cut or gouged. 1.e. Ground the work or metal to be cut or gouged to a good electrical (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 or gouge in or under water. 1.h. When working above floor level, protect yourself from a fall should you get a shock. 1.i. Operate the pilot arc with caution. The pilot arc is capable of burning the operator, others or even piercing safety clothing. 1.j. Also see Items 4c and 6.

ELECTRIC SHOCK can kill.

FUMES AND GASES can be dangerous.

3.a. Plasma cutting or gouging may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases. When cutting or gouging, keep your head out of the fumes. Use enough ventilation and/or exhaust at the arc to keep fumes and gases away from the breathing zone. When plasma cutting or gouging on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes, keep exposure as low as possible and within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanical ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required. Additional precautions are also required when welding on galvanized steel. 3. b. The operation of plasma cutting or gouging fume control equipment is affected by various factors including proper use and positioning of the equipment, maintenance of the equipment and the specific procedure and application involved. Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits. 3.c. Do not use plasma cutting or gouging equipment in locations near chlorinated hydrocarbon vapors coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors to form phosgene, a highly toxic gas, and other irritating products. 3.d. Gases used for plasma cutting and gouging can displace air and cause injury or death. Always use enough ventilation, especially in confined areas, to insure breathing air is safe. 3.e. Read and understand the manufacturers instructions for this equipment and follow your employers safety practices.

2.a. Use safety glasses and a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when performing or observing plasma arc cutting or gouging. Glasses,headshield and filter lens should conform to ANSI Z87. I standards. 2.b. Use suitable clothing including gloves made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays. 2.c. Protect other nearby personnel with suitable non-flammable screening and/or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal.

ARC RAYS can burn.

CUTTING SPARKS can cause fire or explosion.

4.a. Remove fire hazards from the plasma cutting or gouging area. If this is not possible, cover them to prevent the cutting or gouging sparks from starting a fire. Remember that welding sparks and hot materials from plasma cutting or gouging can easily go through small cracks and openings to adjacent areas. Avoid cutting or gouging near hydraulic lines. Have a fire extinguisher readily available. 4.b. Where compressed gases are to be used at the job site, special precautions 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.

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SAFETY
FORELECTRICALLY powered equipment.
6.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 6.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturers recommendations. 6.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturers recommendations.

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4.c. When not cutting or gouging, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard. 4.d. Do not cut or gouge tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even though they have been cleaned. For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances, AWSF4.1 from the American Welding Society (see address above). 4.e. Vent hollow castings or containers before heating, cutting or gouging. They may explode. 4.f. Do nor fuel engine driven equipment near area where plasma cutting or gouging. 4.g. Sparks and spatter are thrown from the plasma arc. Wear safety glasses, ear protection and oil free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs when cutting or gouging out of position or in confined places. Always wear safety glasses with side shields when in a cutting or gouging area. 4.h. Connect the work cable to the work as close to the cutting or gouging area as practical. Work cables connected to the building framework or other locations away from the cutting or gouging area increase the possibility of the current passing through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains or cables until they fail. 4.I. Read and follow NFPA 51B Standard for Prevention During Welding, Cutting and Other Hot Work, available from NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma 022690-9101.

PLASMA ARC can injure.

7.a. Keep your body away from nozzle and plasma arc. 7.b. Operate the pilot arc with caution. The pilot arc is capable of burning the operator, others or even piercing safety clothing.

ELECTRIC AND MAGNETIC FIELDS may be dangerous

8.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Cutting or gouging current creates EMF fields around torch cables and cutting machines. 8.b. EMF fields may interfere with some pacemakers, so operators having a pacemaker should consult their physician before cutting or gouging. 8.c. Exposure to EMFfields during cutting or gouging may have other health effects which are now not known. 8d. All operators should use the following procedures in order to minimize exposure to EMF fields from the cutting or gouging circuit: 8.d.1. Route the torch and work cables together - Secure them 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 and work 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 as possible to the area being cut or gouged. 8.d.5. Do not work next to cutting power source.

CYLINDER may explode if damaged.

5.a. Use only compressed gas cylinders containing the correct gas for the process used and properly operating regulators designed for the gas and pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition. 5.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support. 5.c. Cylinders should be located: Away from areas where they may be struck or subjected to physical damage. A safe distance from plasma cutting or gouging, arc welding operations and any other source of heat, sparks, or flame. 5.d. Never allow any part of the electrode, torch or any other electrically hot parts to touch a cylinder. 5.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve. 5.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use. 5.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l, Precautions for Safe Handling of Compressed Gases in Cylinders,available from the Compressed Gas Association 1235 Jefferson Davis Highway, Arlington, VA 22202.

Refer to http://www.lincolnelectric.com/safety for additional safety information.

NOTES

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SAFETY
PRCAUTIONS DE SRET

iv

Pour votre propre protection lire et observer toutes les instructions et les prcautions de sret specifiques qui parraissent dans ce manuel aussi bien que les prcautions de sret gnrales suivantes: Sret Pour Soudage A LArc 1. Protegez-vous contre la secousse lectrique: a. Les circuits llectrode et la pice sont sous tension quand la machine souder est en marche. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les vtements mouills. Porter des gants secs et sans trous pour isoler les mains. b. Faire trs attention de bien sisoler de la masse quand on soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse. c. Maintenir le porte-lectrode, la pince de masse, le cble de soudage et la machine souder en bon et sr tat defonctionnement. d.Ne jamais plonger le porte-lectrode dans leau pour le refroidir. e. Ne jamais toucher simultanment les parties sous tension des porte-lectrodes connects deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines. f. Si on utilise la machine souder comme une source de courant pour soudage semi-automatique, ces precautions pour le porte-lectrode sapplicuent aussi au pistolet de soudage. 2. Dans le cas de travail au dessus du niveau du sol, se protger contre les chutes dans le cas ou on recoit un choc. Ne jamais enrouler le cble-lectrode autour de nimporte quelle partie du corps. 3. Un coup darc peut tre plus svre quun coup de soliel, donc: a. Utiliser un bon masque avec un verre filtrant appropri ainsi quun verre blanc afin de se protger les yeux du rayonnement de larc et des projections quand on soude ou quand on regarde larc. b. Porter des vtements convenables afin de protger la peau de soudeur et des aides contre le rayonnement de larc. c. Protger lautre personnel travaillant proximit au soudage laide dcrans appropris et non-inflammables. 4. Des gouttes de laitier en fusion sont mises de larc de soudage. Se protger avec des vtements de protection libres de lhuile, tels que les gants en cuir, chemise paisse, pantalons sans revers, et chaussures montantes. 5. Toujours porter des lunettes de scurit dans la zone de soudage. Utiliser des lunettes avec crans lateraux dans les zones o lon pique le laitier.

6. Eloigner les matriaux inflammables ou les recouvrir afin de prvenir tout risque dincendie d aux tincelles. 7. Quand on ne soude pas, poser la pince une endroit isol de la masse. Un court-circuit accidental peut provoquer un chauffement et un risque dincendie. 8. Sassurer que la masse est connecte le plus prs possible de la zone de travail quil est pratique de le faire. Si on place la masse sur la charpente de la construction ou dautres endroits loigns de la zone de travail, on augmente le risque de voir passer le courant de soudage par les chaines de levage, cbles de grue, ou autres circuits. Cela peut provoquer des risques dincendie ou dechauffement des chaines et des cbles jusqu ce quils se rompent. 9. Assurer une ventilation suffisante dans la zone de soudage. Ceci est particulirement important pour le soudage de tles galvanises plombes, ou cadmies ou tout autre mtal qui produit des fumes toxiques. 10. Ne pas souder en prsence de vapeurs de chlore provenant doprations de dgraissage, nettoyage ou pistolage. La chaleur ou les rayons de larc peuvent ragir avec les vapeurs du solvant pour produire du phosgne (gas fortement toxique) ou autres produits irritants. 11. Pour obtenir de plus amples renseignements sur la sret, voir le code Code for safety in welding and cutting CSA Standard W 117.2-1974.

PRCAUTIONS DE SRET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR

1. Relier la terre le chassis du poste conformement au code de llectricit et aux recommendations du fabricant. Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre. 2. Autant que possible, Iinstallation et lentretien du poste seront effectus par un lectricien qualifi. 3. Avant de faires des travaux linterieur de poste, la debrancher linterrupteur la boite de fusibles. 4. Garder tous les couvercles et dispositifs de sret leur place.

Thank You

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for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product as much pride as we have in bringing this product to you!

CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customers particular purpose, with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any warranty with respect to the sale of our products. Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements. Subject to Change This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com for any updated information.

Please Examine Carton and Equipment For Damage Immediately

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received. Please record your equipment identification information below for future reference. This information can be found on your machine nameplate. Product _________________________________________________________________________________ Model Number ___________________________________________________________________________ Code Number or Date Code_________________________________________________________________ Serial Number____________________________________________________________________________ Date Purchased___________________________________________________________________________ Where Purchased_________________________________________________________________________ Whenever you request replacement parts or information on this equipment, always supply the information you have recorded above. The code number is especially important when identifying the correct replacement parts.

On-Line Product Registration

- Register your machine with Lincoln Electric either via fax or over the Internet. For faxing: Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it. For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose Support and then Register Your Product. Please complete the form and submit your registration. Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection. The level of seriousness to be applied to each is explained below:

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

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

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TABLE OF CONTENTS
Page Installation.......................................................................................................................Section A Technical Specifications .......................................................................................................A-1 Safety Precautions ...............................................................................................................A-2 Select Proper Location .........................................................................................................A-2 Stacking................................................................................................................................A-2 Tilting ....................................................................................................................................A-2 High Frequency Interference Protection...............................................................................A-2 Input Electrical Connections .................................................................................................A-2 Gas Input Connections .........................................................................................................A-3 Output Connections..............................................................................................................A-3 Torch .............................................................................................................................A-3 ________________________________________________________________________________ Operation.........................................................................................................................Section B Safety Precautions ...............................................................................................................B-1 Description ...........................................................................................................................B-1 Preheat Temperature for Plasma Cutting.............................................................................B-1 User Responsibility...............................................................................................................B-2 Operational Features and Controls ......................................................................................B-2 Design Features and Advantages ........................................................................................B-2 Cutting Capability .................................................................................................................B-3 Consumable Life ..................................................................................................................B-3 Limitations ............................................................................................................................B-4 Controls and Settings ...................................................................................................B-4, B-5 Cutting Process ............................................................................................................B-5, B-6 Gouging Process ..................................................................................................................B-6 Torch ....................................................................................................................................B-7 Pilot Arc Discussion..............................................................................................................B-7 Procedure Recommendations ..............................................................................................B-7 General .........................................................................................................................B-7 Suggestions for Extra Utility from the TOMAHAWK 1000 System ...........................B-8 Torch Part Configurations ...........................................................................................B-9, B-10 Machine Interface ...............................................................................................................B-11 ________________________________________________________________________________

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Accessories...............................................................................................Section C ________________________________________________________________________ Maintenance ..............................................................................................Section D Safety Precautions ................................................................................................D-1 Routine Maintenance.............................................................................................D-1 Periodic Maintenance ............................................................................................D-1 ________________________________________________________________________ Troubleshooting ..............................................................................................Section E Safety Precautions.................................................................................................E-1 How to Use Troubleshooting Guide.......................................................................E-1 Troubleshooting Guide ...........................................................................E-2 Thru E-7 ________________________________________________________________________ Wiring Diagrams ..............................................................................................Section F Wiring Diagram ......................................................................................................F-1 ________________________________________________________________________ Parts Lists ........................................................................................................Appendix TOMAHAWK 1000 .............................................................................P-627 Series Torch (Hand Held)..........................................................................................P-210-X Torch (Machine Held).....................................................................................P-210-Y ________________________________________________________________________

A-1

INSTALLATION
INPUT - SINGLE PHASE/THREE PHASE/ 50 / 60 HERTZ
Standard Voltage 208V10%-230V 15% / 1 / 50 / 60Hz 208V10%-575V 15% / 3 / 50 / 60Hz Duty Cycle 100% 50% CURRENT AMPS 40A 60A Input Current @ Rated Output 37.8A (Max) @ 50% 20.9A (Max) @ 50% VOLTAGE AMPS 96VDC 104 VDC

A-1

TECHNICAL SPECIFICATIONS -TOMAHAWK 1000

RATED OUTPUT AT 40 C

OUTPUT
Current Range 20 - 60 Amps Open Circuit Voltage 270 VDC Pilot Current 20 Amps

REQUIRED GAS FLOW RATE

80.0 PSI @ 275 SCFH (5.5 Bar. @ 130 20% LITERS/MIN.)

REQUIRED GAS INLET PRESSURE

87.0 to 109.0 PSI (6.0 Bar. to 7.5 Bar.)

RECOMMEND INPUT WIRE AND FUSE SIZES

For all plasma cutting applications Based on U.S. National Electrical Code Ambient Temperature 30oC or Less Output AC Input Voltage at 50/60 Hertz 575V 60 A 208V Input Cord Supplied with Machine Fuse (Super Lag) Circuit Breaker (Delay Type) 30AMPS Type S, SO, ST, STO or Extra Hard Usage Cord AWG (IEC) Sizes Input Supply Wires 1 Ground Wire STO, 600V #10 (5.3 mm2) #10 (5.3 mm2)

PHYSICAL DIMENSIONS
Height Width Depth Weight Including Torch Cable 63.9 lbs. 29 kgs

15.3 in. 389 mm

9.7 in. 247 mm

21.65 in. 550 mm

TEMPERATURE RANGES
OPERATING TEMPERATURE RANGE -10C to +40C STORAGE TEMPERATURE RANGE -25C to +55C

TOMAHAWK 1000

A-2

INSTALLATION

A-2

Read entire Installation Section before installing the TOMAHAWK 1000 .

SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK CAN KILL.

Only qualified personnel should install this machine. Turn the input power OFF at the disconnect switch or fuse box and discharge input capacitors before working inside the equipment. Do not touch electrically hot parts. Turn the TOMAHAWK 1000 Power Switch OFF when connecting power cord to input power. ------------------------------------------------------------------------------------

(1) Make sure the power supply chassis is connected to a good earth ground. The work terminal ground does NOT ground the machine frame. (2) Keep the work clamp isolated from other work clamps that have high frequency. (3) If the work clamp cannot be isolated, then keep the clamp as far as possible from other work clamp connections. (4) When the machine is enclosed in a metal building, several good earth driven electrical grounds around the periphery of the building are recommended. Failure to observe these recommended installation procedures may cause improper function of the TOMAHAWK 1000 or possibly even damage to the control system or power supply components.

INPUT ELECTRICAL CONNECTIONS

The TOMAHAWK 1000 is rated for 208VAC through 575VAC input voltages. Before installing the machine, check that input supply voltage, phase, and frequency are the same as the machine's voltage, phase, and frequency as specified on the machine's rating plate. The TOMAHAWK 1000 should be connected only by a qualified electrician. Installation should be made in accordance with local codes.

SELECT PROPER LOCATION

Place the TOMAHAWK 1000 where clean cool air can freely circulate in and out of the louvers. Dirt, dust or any foreign material that can be drawn into the machine should be kept at a minimum. Failure to observe these precautions can result in excessive operating temperatures and nuisance shutdown of the machine. A source of clean, dry air or nitrogen must be supplied to the TOMAHAWK 1000. Oil in the air is a severe problem and must be avoided. The supply pressure must be between 80 and 110 psi. The flow rate is approximately 4.0 cfm (113 l/min.). Failure to observe these precautions could result in excessive operating temperatures or damage to the torch.

INPUT PLUG INSTALLATION

POWERCORDCONNECTION A power cord is provided and wired into the machine. Follow the power cord connection instructions. Single Phase Input Connect green lead to ground per National Electrical Code. Connect black and red leads to power. Wrap white lead with tape to provide 600V insulation. Three Phase Input Connect green lead to ground per National Electric Code. Connect black, red and white leads to power.

STACKING
The TOMAHAWK 1000 cannot be stacked.

TILTING
The TOMAHAWK 1000 must be placed on a stable, level surface so it will not topple over.

WARNING
Failure to wire as instructed may cause personal injury or damage to equipment. To be installed or checked by an electrician or qualified person only. -----------------------------------------------------------------------------------In all cases, the green or green/yellow grounding wire must be connected to the grounding pin of the plug, usually identified by a green screw.

HIGH FREQUENCY INTERFERENCE PROTECTION

The TOMAHAWK 1000 employs a touch start mechanism for arc initiation which eliminates high frequency emissions from the machine as compared with spark gap and solid state type high frequency generators. Keep in mind, though, that these machines may be used in an environment where other high frequency generating machines are operating. By taking the following steps, high frequency interference into the TOMAHAWK 1000 can be minimized

TOMAHAWK 1000

A-3

INSTALLATION

A-3

Attachment plugs must comply with the Standard for Attachment Plugs and Receptacles, UL498. The product is considered acceptable for use only when an attachment plug as specified is properly attached to the supply cord.

ENGINE DRIVEN GENERATOR

For use on engine drives, keep in mind the above input draw restrictions and the following precaution. The TOMAHAWK 1000 can be operated on engine driven generators as long as the 230 volt auxiliary meets the following conditions: The AC waveform peak voltage is below 400 volts. The AC waveform frequency is between 45 and 65 Hz. The following Lincoln engine drives meet these conditions when run in the high idle mode: Outback 185, Ranger 225, Ranger 250, 250LPG, 305G and 305D engine drives. Vantage 300, 400, 500 and Air Vantage engine drives. Some engine drives do not meet these conditions (eg Miller Bobcats, etc). Operation of the TOMAHAWK 1000 is not recommended on engine drives not conforming to these conditions. Such combinations may overvoltage the TOMAHAWK 1000 power source.

If these filter ratings are unavailable, anything with a rating less than, or equal to, 20 micron would be acceptable to use. In line filter elements will generally filter the air with little restriction to the airflow until the element is about 75% contaminated. After this point, there will be a noticeable pressure drop in the line. Filter elements should be replaced when a pressure drop of 8-10 psi is indicated; however, for optimum performance of the TOMAHAWK 1000, the filter element should be replaced at or before the pressure drop reaches 8 psi. Be sure to select a filter that will accommodate the necessary flow rating for the TOMAHAWK 1000 as specified in the Installation section of this instruction manual under the Gas Input Connections heading. NOTE: When using nitrogen gas from a cylinder, the cylinder must have a pressure regulator. Maximum psi from a nitrogen gas cylinder to the TOMAHAWK 1000 regulator should never exceed 110 psi. Install a hose between the nitrogen gas cylinder regulator and the TOMAHAWK 1000 gas inlet. CYLINDER could explode if damaged.

WARNING
Keep cylinder upright and chained to a fixed support. Keep cylinder away from areas where it could be damaged. Never lift machine with cylinder attached. Never allow the cutting torch to touch the cylinder. Keep cylinder away from live electrical parts. Maximum inlet pressure 110 psi. ------------------------------------------------------------------------

GAS INPUT CONNECTIONS

(External Air Supply)
Supply the TOMAHAWK 1000 with clean compressed air or nitrogen. Supply pressure must be between 80 psi and 110 psi. Flow rate should be approximately 275 SCFH (130 20% LITERS/MIN.). NOTE: Oil in the air supply to the TOMAHAWK 1000 can cause severe problems. Use only a clean air supply. Compressed gas can be supplied either through the air fitting supplied with the machine or through the 1/4-19 BSPP thread at the rear of the machine. To use the air fitting supplied with the machine (packaged in the consumable kit), apply teflon tape to the fitting threads and install the fitting in the port at the rear of the machine. If compressed air is being used, it is highly recommended that an in line filter be installed in the air supply line ahead of the air connection to the TOMAHAWK 1000. A standard nominal 5 micron in line filter is recommended; however, for optimum performance, select a prefilter with a 3 micron absolute rating.

OUTPUT CONNECTIONS
Torch
The TOMAHAWK 1000 is sent from the factory with a cutting torch and work clamp included. The work clamp must be securely connected to the work piece. If the work piece is painted or extremely dirty it may be necessary to expose the bare metal in order to make a good electrical connection.

TOMAHAWK 1000

B-1

OPERATION
DESCRIPTION

B-1

SAFETY PRECAUTIONS WARNING

ELECTRIC SHOCK can kill. Do not touch electrically live parts or electrode with skin or wet clothing. Insulate yourself from work and ground. Always wear dry insulating gloves. FUMES AND GASES can be dangerous. Keep your head out of fumes. Use ventilation or exhaust to remove fumes from breathing zone. WELDING, CUTTING and GOUGING SPARKS can cause fire or explosion Keep flammable material away. Do not weld, cut or gouge on containers that have held combustibles. ARC RAYS can burn. Wear eye, ear and body protection. PLASMA ARC can injure Keep your body away from nozzle and plasma arc. Operate the pilot arc with caution. The pilot arc is capable of burning the operator, others or even piercing safety clothing. Observe additional Safety Guidelines detailed in the beginning of this manual.

The TOMAHAWK 1000 is a constant current, continuous control plasma cutting power source. It provides superior and reliable starting characteristics, cutting visibility and arc stability. The control system has a safety mechanism to insure that the nozzle and electrode are in place before cutting or gouging. This is extremely important due to the high voltages involved. The TOMAHAWK 1000 comes standard with an air regulator and pressure gauge. The machine also comes with an input power cord and Hand-held torch with a 25 Ft.(7.6m) cable length. Consumables are included with each TOMAHAWK 1000 purchase so that cutting can begin right out of the box. Consumables can also be ordered as individual packages. The TOMAHAWK 1000 initiates the plasma arc with a simple, yet reliable, touch start mechanism. This system eliminates many of the failure problems associated with hi-frequency start systems.

PREHEAT TEMPERATURE FOR PLASMA CUTTING

Preheat temperature control is not necessary in most applications when plasma arc cutting or gouging. Preheat temperature control may be necessary on high carbon alloy steels and heat treated aluminum for crack resistance and hardness control. Job conditions, prevailing codes, alloy level, and other considerations may also require preheat temperature control. The following minimum preheat temperature is recommended as a starting point. Higher temperatures may be used as required by the job conditions and/or prevailing codes. If cracking or excessive hardness occurs on the cut face, higher preheat temperature may be required. The recommended minimum preheat temperature for plate thickness up to 1/2" (12.7mm) is 70F (21.1C).

Duty Cycle
The duty cycle of a plasma machine is the percentage of time in a 10 minute cycle at which the operator can operate the machine at rated cutting current. Example: 60% duty cycle means that is possible cut for 6 minutes, then the machine stops for 4 minutes. Refer to the Technical Specification section for more information about the machine rated duty cycles.

TOMAHAWK 1000

B-2

OPERATION

B-2

USER RESPONSIBILITY
Because design, fabrication, erection and cutting variables affect the results obtained in applying this type of information, the serviceability of a product or structure is the responsibility of the user. Variation such as plate chemistry, plate surface condition (oil, scale), plate thickness, preheat, quench, gas type, gas flow rate and equipment may produce results different than those expected. Some adjustments to procedures may be necessary to compensate for unique individual conditions. Test all procedures duplicating actual field conditions.

DESIGN FEATURES AND ADVANTAGES

The TOMAHAWK 1000 design makes plasma cutting uncomplicated. This list of design features and advantages will help you understand the machine's total capabilities so that you can get maximum use from your machine. - Light weight and portable design for industrial use. - Continuous control, 20 - 60 amps. - Reliable touch start mechanism for plasma arc initiation. - 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 installation of consumables and torch. - Preflow/Postflow timing. Preflow is eliminated if arc is re-initiated in Postflow. - Thermostatic Protection. - Solid state over-current protection. - Unique electrode and nozzle design for optimum cooling and long life.

TOMAHAWK 1000

B-3

OPERATION
CONSUMABLE LIFE

B-3

CUTTING CAPABILITY
The TOMAHAWK 1000 is rated at 60 amps, at 50% duty cycle on a 10 minute basis. If the duty cycle is exceeded, a thermal protector will shut off the output of the machine until it cools to the normal operating temperature. Figure B.1 shows the cut capacity of the TOMAHAWK 1000 when cutting mild steel.

The expected life for the TOMAHAWK 1000 's electrode under normal operating conditions is approximately 1000 starts/cuts. An erosion of .060" is typical for end of electrode life, however, the electrode life may last longer. A green and erratic arc will indicate definite electrode failure and the electrode should be replaced immediately. It is recommended that consumables be replaced in complete sets. (Example: Electrode and Nozzle). This will maximize the performance of the TOMAHAWK 1000 system.

Figure B.1

Tomahawk 1000 - Cut Capacity Chart Recommended Torch Travel Speed (IPM)
40 30 20 10 0 0.500

aaron neville you tube

0.625

0.750 Metal Thickness (inches)

0.875

1.000

Tomahawk 1000
1 1/2 1 1/4 1

3/4 1/2 1/4 0 Recommended Cut @19 IPM Max Cut @ 10 IPM Sever Cut @ 5 IPM

TOMAHAWK 1000

B-4

OPERATION
3. Output red LED: The cutting torch is energized.
A

B-4

LIMITATIONS
Do not exceed output current and duty cycle rating of machine. Do not use the TOMAHAWK 1000 for pipe thawing.

CONTROLS AND SETTINGS

(Figure B.2) TOMAHAWK 1000 front command panel. FIGURE B.2

Blinking: Internal auxiliary undervoltage condition. The machine needs to be turned OFF then ON again to restart. 4. Thermal yellow LED: The machine is overheated and the output has been disabled. This usually occurs when the duty cycle of the machine has been exceeded. Leave the machine ON to allow the internal components to cool. When the thermal LED turns off, normal operation is again possible. 5. Gas Pressure yellow LED: The Input Gas pressure is out of range. The machine will restart automatically when a correct gas pressure is detected. To check/adjust the primary gas pressure (see recommended values in the Technical Specifications of this manual): When this LED illuminates, the machine will automatically enter into Purge mode for 10 seconds. During Purge time verify and adjust the gas pressure using the gas pressure regulator knob. If necessary, also verify and adjust the inlet gas pressure to the unit. 6. Parts In Place (PIP) yellow LED: Torch consumables are not attach correctly. To reset the machine: Firmly attach the torch shielding Cup by hand. Do not over tighten. After the torch is restored, the machine will restart after 5 seconds. During this time the PIP LED will blink. Note: When the LED is blinking, if another PIP error occurs or if the Torch Trigger pushbutton is pressed the machine will return to the error condition: PIP LED returns to steady ON and the restoring procedure repeats. When the PIP LED turns OFF the machine is ready to operate.

2 8 3 4

5 7 6 1
When the machine is turned ON, an auto-test is executed; during this test all of the LEDs on the Control Panel light up. 1. Output Current Knob: For setting the output current used during cutting. Refer to the Technical Specification section for more information about the machines rated current range. Air, Gas Purge: The Output Current Knob completely rotated counterclockwise enables the air purge function. A five minute timeout stops the purge function; this will occur only if the Output Current Knob remains in the purge mode for an extended time. 2. Power ON/OFF green LED: Illuminates when the machine is ON.

Blinking: Input voltage out of range condition. The machine is disabled: When the input voltage returns to the correct range, the machine will restart automatically. Note: The Fan may automatically turn OFF if the error condition persists for more than 2 seconds.

TOMAHAWK 1000

B-5

OPERATION
WARNING

B-5

7. Primary Air, Gas Pressure Gauge and Regulator Knob: Allows the regulation and monitoring of the primary air/gas pressure. The inlet primary air/gas pressure is limited by this pressure regulator, set at the factory to 80 PSI (5.5 bar). To adjust the air/gas pressure, place the machine in Purge mode. 8. Cutting Operating Mode Selection: Press the pushbutton to select the desired operating mode (the LED indicates the selected mode): CUT (Upper LED): for cutting or piercing operations on a solid work piece. GRID (Middle LED): for cutting operations on a grid work piece. GOUGE (Lower LED): for removing material from a solid work piece (removing a weld). The Operating Mode can only be changed with the machine at idle or during Purge or Post Flow times. Pressing the pushbutton during Pilot Arc or Cutting will have no effect. Items 9 thru 12 on the back of the TOMAHAWK 1000 (See Figure B.3) 9. Fan: Provides machine cooling. When the machine is switched ON, the fan runs continuously. 10. Power Switch: Turns ON / OFF the input power to the machine. 11. Input cable: Connects unit to the input power. 12. Air or Gas Inlet: Compressed Air or Gas Connection. FIGURE B.3

1MPa = 145 psi

Clean, dry air or gas must be supplied to the machine. A pressure setting above 110 PSI (7.5 bar) could damage the torch. Failure to observe these precautions could result in excessive operating temperatures or damage to the torch. ------------------------------------------------------------------------

CUTTING PROCESS
The air plasma cutting process uses air or nitrogen as a cutting gas and to cool the torch. The pilot arc is initiated as follows: The torch trigger energizes a solenoid valve. This valve enables the gas to flow during the cutting and post-flow stages. The TOMAHAWK 1000 provides constant current at the set value, independent of the plasma arc length. When preparing to operate, make sure you have all materials needed to complete the job and have taken all safety precautions. Install the machine as instructed in this manual and remember to attach the work clamp to the work piece. With the machine switched OFF, prepare the torch with the consumables adequate to the desired process (CUT / GRID / GOUGE). Refer to the consumable Charts on pages B-9, B-10. Connect the Torch and the work cable to the machine. Turn ON the Power Switch on the back of the machine; the Input Power LED on the front panel will illuminate. The unit is now ready to operate. Verify correct gas pressure using the Gas Purge function. Select the desired process using Operating Mode pushbutton. Set the desired cutting current using the Output Current knob. To start the selected process pull the torch trigger, making sure you are not aiming the torch in an unsafe manner. Once the process is completed releasing the torch trigger will cause the plasma arc to turn off. The gas flow will continue, allowing the torch to cool.

10 12 11 9

TOMAHAWK 1000

B-6

OPERATION
5 - 15 Leading Angle

B-6

The Post Flow time is proportional to the selected cutting current and it is divided into 4 time ranges: Selected Cutting Current Less than 30A Between 30A and 40A Between 40A and 50A Greater than 50A Post Flow Time 15 seconds 20 seconds 25 seconds 30 seconds

Direction of Travel 1/16

Pilot Arc - The air will flow for a preflow time of 2 seconds and the pilot arc will start. (Exceptions: the first time that the trigger is pulled after the machine is turned on, or after a thermal, the initial trigger will be ignored. This is a safety feature to prevent the pilot arc from firing unexpectedly. The other exception is if the machine is in postflow, then the preflow time is skipped and the pilot arc will start immediately.) - The pilot arc will run for 3.0 seconds and shut off unless the arc is brought in contact with the work and the arc is transferred. Avoid excessive pilot arc time by transferring the arc to the workpiece quickly. This will extend consumable life. - When the arc is brought within 1/8 - 1/4" from the work piece the arc will transfer, the current will ramp to the setting on the control panel, and the cut can last indefinitely (or until the duty cycle of the TOMAHAWK 1000 is exceeded). Pierce the work piece by slowly lowering the torch onto the metal at a 300 angle away from the operator. This will blow the dross away from the torch tip. Slowly rotate the torch to vertical position as the arc becomes deeper.
TORCH AT 30 ANGLE TO PIERCE
0

10 - 20

Arc Lag

Use a 5 - 15 leading angle in the direction of the cut. Finish the cut to be made and release the trigger. If the dross is difficult to remove, reduce the cutting speed. High speed dross is more difficult to remove than low speed dross.

PROCESS GOUGING
Gouging is a process used to remove material without cutting entirely through the workpiece. The Tomahawk 1000 has the capability of performing plasma gouging with the proper consumables attached to the torch. In general, gouging consumables provide a wider plasma arc compared to a cutting arc. As the material melts, it is blown forward by the pressurized gas coming out of the torch. The dross will land on the surface of the workpiece and can easily be removed after the gouging process is complete. Technique: Hold the torch at a 45 angle to the workpiece. Pull the torch trigger to start the gouging arc. As the material is removed move the torch forward to continue removing material. When the desired amount of material has been removed, release the torch trigger to stop the gouging process. Typically, the larger the angle between the torch and the workpiece, the deeper and slower the gouging. As the torch angle is decreased, less material is removed and the travel speeds can be increased. Keeping the torch fixed while moving forward will remove a straight line of material. Using a side-toside, weaving motion will remove a wider area of material. The output of the Tomahawk 1000 can also be increased or decreased to control the amount of material being removed. Most users tend to maximize the output in order to remove the most material in a short amount of time.

300

ROTATE TO 0 90 ANGLE TO CUT

90

VERTICAL VERTICAL ANGLE FOR CUTTING

CUT

Keep moving while cutting. Cut at a steady speed without pausing. Maintain the cutting speed so that the arc lag is 10 to 20 behind the travel direction.

TOMAHAWK 1000

B-7
Applications:

OPERATION
PILOT ARC DISCUSSION

B-7

Removing weld imperfections cracks, porosity, inclusions, etc. Back gouging for welding preparation Removal of temporary fit up methods tack welds, bracketing, etc.

WARNING
ELECTRIC SHOCK CAN KILL. Turn off machine at the disconnect switch on the rear of the machine before tightening, cleaning or replacing consumables. ----------------------------------------------------------------------------

The TOMAHAWK 1000 has a smooth, continuous pilot arc. The pilot arc is only a means of transferring the arc to the workpiece for cutting. Repeated pilot arc starts, in rapid succession, is not recommended as these starts will generally reduce consumable life. Occasionally, the pilot arc may sputter or start intermittently. This is aggravated when the consumables are worn or the air pressure is too high. Always keep in mind that the pilot arc is designed to transfer the arc to the workpiece and not for numerous starts without cutting. The TOMAHAWK 1000 does not utilize high frequency starting. When the pilot arc is started, a slight impulse will be felt in the torch handle. This occurrence is normal and is the mechanism which starts the plasma arc. This impulse can also be used to help troubleshoot a "no start" condition.

TORCH
Clean spatter and scale from the nozzle frequently. During operation, if the Parts in Place Yellow LED light together: Check the assembly of the torch consumables. If they are not properly in place, the machine will not start. Make sure that the shield cup is hand tight. Do not use pliers or over tighten. Check the conditions on the inside of the nozzle. If debris has collected, rub the inside of the nozzle to remove any oxide layer that may have built up. Refer to "Suggestions for Extra Utility from the TOMAHAWK 1000 system". Check the condition of the electrode. If the end has a crater-like appearance, replace it along with the nozzle. The maximum wear depth of the electrode is approximately .062. A green and erratic arc will indicate definite electrode failure and the electrode should be replaced immediately. Replace the nozzle when the orifice exit is eroded away or oval shaped. After the problem is found, or if there is nothing apparently wrong, the machine may need to be reset by turning the power switch OFF and then ON again. (It is possible for electrical noise to trip the safety circuit on rare occasions. This should not be a regular occurrence.) If the machine does not reset or continues to trip, consult the Troubleshooting Section. Use the proper cutting procedures referred to in Procedure Recommendations.

PROCEDURE RECOMMENDATIONS
When properly used, plasma arc cutting is a very economical process. Improper use will result in a very high operating cost.

General - In All Cases

Follow safety precautions as printed throughout this operating manual and on the machine. If piercing is required, slowly lower the torch at an angle of about 30 to blow the dross away from the torch tip and slowly rotate the torch to a vertical position as the arc becomes deeper. This process will blow a lot of molten metal and dross. Be careful! Blow the dross away from the torch, the operator and any flammable objects. The nozzle should not be dragged on the metal surface. A drag spacer is provided to maintain a consistant touch height. Refer to Touch Parts Configurations in this Section.
Torch Standoff

1/16 Standoff DRAG thru 1/16" Standoff TOMAHAWK 1000

B-8

OPERATION

B-8

Where possible, start the cut from the edge of the work piece. Keep moving! A steady speed is necessary. Do not pause.

Set air pressure to recommended setting. A higher or lower pressure will cause turbulence in the plasma arc, eroding the orifice of the nozzle tip. Use only Lincoln consumable parts. These parts are patented and using any other replacement consumables may cause damage to the torch or reduce cut quality.

Suggestions for Extra Utility from the TOMAHAWK 1000 System:

WARNING
ELECTRIC SHOCK CAN KILL. Turn off machine at the disconnect switch on the rear of the machine before tightening, cleaning or replacing consumables. ---------------------------------------------------------------------------1. Occasionally an oxide layer may form over the tip of the electrode, creating an insulating barrier between the electrode and nozzle. This will result in false starts. When this happens turn the power off, remove the shield cup and nozzle. Rub the inside surface of the nozzle, this will help remove any oxide buildup. Also, clean any oxide build up from the electrode. Replace the shield cup and nozzle, turn on the power and continue cutting. If false starts continue to occur after cleaning the consumables, then replace them with a new set. Do not continue to try and cut with excessively worn consumables as this can cause damage to the torch head and will degrade cut quality. Do not allow torch cable or body to contact hot surfaces. 2. To improve consumable life, here are some suggestions that may be useful: Make sure the air supply to the TOMAHAWK 1000 is clean and free of oil. Use several extra in line filters if necessary. Minimize dross buildup on the nozzle tip by starting the cut from the edge of the plate when possible. Pierce cutting should be done only when necessary. If piercing, angle torch about 30 from the plane perpendicular to the work piece, transfer the arc, then bring the torch perpendicular to the work and begin parallel movement. Reduce the number of pilot arc starts without transferring to the work. Reduce the pilot arc time before transferring to the work.

TOMAHAWK 1000

B-9

OPERATION
TORCH PART CONFIGURATIONS

B-9

Different hand held torch configurations are available depending on the cutting or gouging application. Standard Cutting Setup: In the Standard Cutting configuration the nozzle is designed not to touch the work piece. The advantage of this cutting method is good visibility of the arc. However it requires a steady hand to avoid touching the nozzle to the work piece which will cause premature nozzle wear and a jagged cut. An optional drag spacer can be attached to the retaining cap to maintain a consistent arc height.

Contact Cutting Setup: Contact Cutting uses special expendable parts that allow the torch to touch the work piece. The advantage of contact cutting is that the torch can touch the work piece, steadily dragging it across the surface. The disadvantage of contact cutting is the plasma arc is not as visible as with a standard torch set-up. There are two types of contact cutting: 1. Direct contact. A special non-insulated nozzle is used that can touch the work piece directly. This set up is designed for applications below 40 amps. 2. Shielded contact. A special insulated nozzle is used in conjunction with a special drag shield. Shielded contact set-ups are for applications greater than 40 amps.

www.lincolnelectric.com

TOMAHAWK 1000

B-10

OPERATION
GOUGING SETUP:

B-10

If gouging metal and not cutting completely through the part is required, a special gouging nozzle is used in conjunction with a gouge shield to protect the nozzle from molten metal blow back.

Refer to the torch parts decal located on your machine or the parts pages at the back of this manual for the specific part numbers required for each of these setups. ALWAYS USE GENUINE LINCOLN ELECTRIC ELECTRODES, NOZZLES, AND EXPENDABLE PARTS FOR THE BEST CUTTING PERFORMANCE.

www.lincolnelectric.com

TOMAHAWK 1000

B-11

OPERATION

B-11

MACHINE INTERFACE
The TOMAHAWK 1000 comes standard with a machine interface. Interface signals provided include: arc start, arc initiated, and arc voltage. These signals are accessible through the 14 pin connector on the case front.

ARC START:
The Arc Start circuit allows for triggering of the power source to commence cutting. This circuit can be accessed through pins K and M of the 14 pin connector. The circuit has a 15 VDC nominal open circuit voltage and requires a dry contact closure to activate.

ARC INITIATED:
The Arc Initiated circuit provides information as to when a cutting arc has transferred to the work piece. This circuit can be accessed through pins I and J of the 14 pin connector. The circuit provides a dry contact closure when the arc has transferred. Input to this circuit should be limited to 0.3 A for either 120VAC or 30VDC.

ARC VOLTAGE:
The Arc Voltage circuit can be used for activating a torch height control. This circuit can be accessed through pins D and G of the 14 pin connector. The circuit provides full electrode to work arc voltage (no voltage divider, 270VDC maximum).
Arc Start M I L H C N G E F K J Arc Initiated

Arc Voltage 14-PIN BOX RECEPTACLE, FRONT VIEW

Users wishing to utilize the Machine Interface can order a K867 Universal Adapter (please adhere to the pin locations stated above) or manufacture a 14 pin connector cable assembly.

TOMAHAWK 1000

C-1

ACCESSORIES

C-1

GENERAL OPTIONS /ACCESSORIES

The following options/accessories are available for your Tomahawk Plasma cutter from your local Lincoln Distributor. K2886-1 - Plasma Circle Cutting Kit - For cutting circles from 3 to 33 in diameter (77mm to 838mm). TORCHES The following replacement or optional torches are available: K2848-1 LC65 Handheld Plasma Torch 25' (7.5m) K2848-2 LC65 Handheld Plasma Torch 50' (15m) K2848-3 LC65M Mechanized Plasma Torch 25' (7.5m) EXPENDABLE PARTS Refer to the torch parts decal located on your machine or the parts pages at the back of this manual for the specific part numbers required for each of these setups.

TOMAHAWK 1000

D-1

MAINTENANCE
WARNING PERIODICMAINTENANCE WARNING

D-1

ELECTRIC SHOCK CAN KILL. Have an electrician install and service this equipment. Turn the input power off at the fuse box before working on equipment. Do not touch electrically hot parts. ---------------------------------------------------------------------

ROUTINEMAINTENANCE
1. Keep the cutting or gouging area and the area around the machine clean and free of combustible materials. No debris should be allowed to collect which could obstruct air flow to the machine. 2. Every 6 months or so, the machine should be cleaned with a low pressure airstream. Keeping the machine clean will result in cooler operation and higher reliability. Be sure to clean these areas: - Printed circuit boards and heat sinks - Power switch

ELECTRIC SHOCK CAN KILL. Turn off machine at the disconnect switch on the rear of the machine before tightening, cleaning or replacing consumables. ---------------------------------------------------------------------------Change consumables as required.

THERMAL PROTECTION
Thermal Detection Devices protect the machine from excessive operating temperatures. Excessive temperatures may be caused by a lack of cooling air or operating the machine beyond the duty cycle and output rating. If excessive operating temperatures should occur, the yellow thermal LED will light and the Detection Devices will prevent output voltage or current. These Detection Devices are self-resetting once the machine cools sufficiently. If the thermostat shutdown was caused by excessive output or duty cycle and the fan is operating normally, the Power Switch may be left on and the reset should occur within a 15 minute period. If the fan is not turning or the air intake louvers were obstructed, then the power must be switched off and the fan problem or air obstruction must be corrected.

CAUTION
When using a low pressure air stream, wear appropriate eye protection. -----------------------------------------------------------------------3. Examine the sheet metal case for dents or breakage. Repair the case as required. Keep the case in good condition to insure that high voltage parts are protected and correct spacings are maintained. All external sheet metal screws must be in place to insure case strength and electrical ground continuity. 4. Inspect the cable periodically for any slits or puncture marks in the cable jacket. Replace if necessary. Check to make sure that nothing is crushing the cable and blocking the flow of air through the air tube inside. Also, check for kinks in the cable periodically and relieve any so as not to restrict the flow of air to the torch.

TOMAHAWK 1000

E-1

TROUBLESHOOTING

E-1

HOW TO USE TROUBLESHOOTING GUIDE WARNING

Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual. __________________________________________________________________________ This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below. Step 1. LOCATE PROBLEM(SYMPTOM). Look under the column labeled PROBLEM (SYMPTOMS). This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the symptom that the machine is exhibiting. Step 2. POSSIBLE CAUSE. The second column labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom. Step 3. RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause, generally it states to contact you local Lincoln Authorized Field Service Facility. If you do not understand or are unable to perform the Recommended Course of Action safely, contact you local Lincoln Authorized Field Service Facility.

WARNING
ELECTRIC SHOCK CAN KILL. Turn off machine at the disconnect switch on the rear of the machine and remove main power supply connections before doing any troubleshooting. ----------------------------------------------------------------------------

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. TOMAHAWK 1000

E-2 PROBLEMS (SYMPTOMS)

TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual

E-2 RECOMMENDED COURSE OF ACTION

POSSIBLE AREAS OF MISADJUSTMENTS

Input circuit breaker trips repeatedly. 1. This may be normal. If output is set to maximum a 30 amp circuit is required. See Technical Specification page. 2. Install a larger input circuit or turn the output control to a lower amperage. No Status indicators light and the fan 1. Check the input power to be sure does not operate 5 seconds after the it is on. power switch is turned on. 2. Check the power line fuses or breakers and machine connection. 3. Disconnect input power at fuse/breaker panel and check line switch continuity. Replace line switch if bad. No Status indicators light 5 seconds 1. Possible faulty Control Board. after the power switch is turned on, but the fan operates. The Thermal LED does not go out. 1. Possible faulty Control board.

If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. TOMAHAWK 1000

E-3 PROBLEMS (SYMPTOMS)

TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual

E-3 RECOMMENDED COURSE OF ACTION

POSSIBLE AREAS OF MISADJUSTMENTS

The TOMAHAWK 1000 powers 1. Turn the output knob to purge up properly but there is no response zone on the front of the TOMAwhen the trigger is pulled and only HAWK 1000 . If air does not the POWER LED is lit. flow, then: The main gas solenoid assembly/pressure sensor may be faulty. Check or replace. Possible faulty Control board. 2. Remove the handles (or barrel) of the torch and examine all the connections. 3. Check for proper trigger switch operation. Replace the trigger switch or torch cable if defective. 4. Possible faulty Control board. If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. TOMAHAWK 1000

E-4 PROBLEMS (SYMPTOMS)

TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual

E-4 RECOMMENDED COURSE OF ACTION

POSSIBLE AREAS OF MISADJUSTMENTS

When the trigger is pulled air begins 1. Check the torch consumables to be to flow, but there is no pilot arc after sure they are not dirty or greasy, at least 3 seconds. and are in good shape. Replace the consumables if necessary. 2. Make sure the air pressure is set correctly. 3. Make sure there are no kinks or restrictions for air flow in the torch cable. Replace cable as needed. 4. If a slight thump cannot be felt in the torch when the trigger is pulled, check for loose connection in the torch head. 5. Possible faulty Control board.

The air begins to flow and there is a 1. Check the torch consumables to very brief arc that snaps out consis- be sure they are in tight, not dirty tently with repeated trigger pulls. or greasy and in good shape. Replace if necessary. If all recommended possible areas of 2. Make sure the air pressure is set misadjustment have been checked correctly. and the problem persists, Contact your local Lincoln Authorized 3. Possible faulty in Control board. Field Service Facility. The arc starts but sputters badly. 1. Check the torch consumables to be sure they are in tight, not dirty or greasy and in good shape. Replace if necessary. 2. Check air supply for oil or a great deal of water. If there is oil or a great deal of water, the air must be filtered or the machine switched to nitrogen or bottled air. 3. Make sure the air pressure is set correctly.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. TOMAHAWK 1000

E-5 PROBLEMS (SYMPTOMS)

TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual

E-5 RECOMMENDED COURSE OF ACTION

POSSIBLE AREAS OF MISADJUSTMENTS

Pilot arc starts but will not transfer 1. Check work lead connection for when brought near work. clean, secure connection. 2. Plasma will only cut conductive material. Do not attempt to cut fiberglass, plastic, rubber, PVC or any other non-conductive material. If all recommended possible areas of misadjustment have been checked 3. Make sure work piece is clean and the problem persists, Contact and dry. Remove any scale, rust your local Lincoln Authorized or dross. Field Service Facility. 4. Check all connections to Control board. 5. Possible faulty Control board.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. TOMAHAWK 1000

E-6

TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual

E-6

SYMPTOM

STATUS BOARDINDICATORS CHECK

Yellow Gas Pressure LED is lit and steady. 1. Make sure there is at least 80 psi connected to the gas connection at the back of the machine. 2. Turn the output knob to the purge zone and set the regulator to the correct pressure. The pressure may increase when air stops flowing but this is normal. Do not reset the pressure while the air is OFF. 3. Possible faulty Pressure Switch. 4. Possible faulty Control board. The Yellow Parts In Place LED is lit and steady. 1. Verify Torch consumables are in good condition and properly installed. If torch and consumables are properly installed, the Yellow LED should turn off. The unit may be required to have the input power turned off then back on. Normal cutting or gouging can resume. 1. The machine's thermostat has tripped due to exceeded duty cycle limits. Do NOT turn the power off. Allow the machine to cool for 15 - 30 minutes and the thermostat will reset itself. 2. The machine's air louvers or fans are obstructed such that air cannot flow to properly cool the machine. Remove any foreign material that may block air flow. Blow the machine out with a clean, dry air stream. 3. Possible faulty Control board.

The Thermal LED is lit.

Error condition list. At first, try turning the machine OFF, wait for a few seconds, then turn the machine ON again. If the error remains, troubleshooting is required. Please contact the nearest technical service center or Lincoln Electric and report the LED Status found on the machine Front Panel.

On (Green LED)
Head Torch

Blink (Red LED)

Blink (Yellow)

1. This occurs if after 4 seconds the Pilot Arc isnt transfered to the workpiece. The machine stops the pilot arc to avoid overheating the Torch Head. 2. To restore the machine: Release the Torch Trigger pushbutton. The blinking LEDs will change to steady ON. Pull the Torch Trigger and verify correct operation.

TOMAHAWK 1000

E-7

TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual

E-7

Error condition list

V

On (Green LED)
No pilot arc established

On (Yellow LED)

On (Yellow LED)

1. The Torch Trigger pushbutton is pressed. During this period the machine will attempt to start the pilot arc for 4 times. If the pilot arc does not start, the machine automatically will enter into a safe status condition that will allow troubleshooting as necessary. 2. To restore the machine: Turn OFF the Power switch. Check the correct placement of the Torch Head consumables and parts. Check the Torch electrical connections. Turn ON the machine.

On(Green LED) On (Yellow LED) On (Yellow LED) On (Yellow LED)

Trigger Pushed 1. This occurs if the machine is turned ON (or if it is restarted after Thermal reset) with the Torch Trigger pulled. This condition avoids unsafe operating conditions. The machine is disabled such that manual cutting or gouging processes can ONLY be initiated under the direct control of the operator. 2. To restore the machine: Release the Torch Trigger. The LEDs will return to normal status and cutting or Gouging may resume. 3. If this error condition persists, check for eventual malfunctions of the Torch Trigger pushbutton.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. TOMAHAWK 1000

F-1

DIAGRAMS

TOMAHAWK 1000

ENHANCED DIAGRAM

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

F-1

 Do not touch electrically live parts or

Keep flammable materials away.

Wear eye, ear and body protection.

WARNING
Spanish

electrode with skin or wet clothing. Insulate yourself from work and ground.
No toque las partes o los electrodos Mantenga el material combustible Protjase los ojos, los odos y el

AVISO DE PRECAUCION
French

bajo carga con la piel o ropa mojada. Aislese del trabajo y de la tierra.
Ne laissez ni la peau ni des vte-

fuera del rea de trabajo.

cuerpo.

Gardez lcart de tout matriel

Protgez vos yeux, vos oreilles et

ATTENTION
German

ments mouills entrer en contact avec des pices sous tension. Isolez-vous du travail et de la terre.
Berhren Sie keine stromfhrenden

inflammable.

votre corps.

Entfernen Sie brennbarres Material!

Tragen Sie Augen-, Ohren- und Kr-

WARNUNG
Portuguese

Teile oder Elektroden mit Ihrem Krper oder feuchter Kleidung! Isolieren Sie sich von den Elektroden und dem Erdboden!
No toque partes eltricas e electro Mantenha inflamveis bem guarda-

perschutz!

Use proteo para a vista, ouvido e

ATENO
Japanese

dos com a pele ou roupa molhada. Isole-se da pea e terra.

dos.

corpo.

Chinese

Korean

Arabic

READ AND UNDERSTAND THE MANUFACTURERS INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYERS SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR. LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR. LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HERSTELLERS. DIE UNFALLVERHTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

 Keep your head out of fumes. Use ventilation or exhaust to

Turn power off before servicing.

Do not operate with panel open or

guards off.

remove fumes from breathing zone.

Los humos fuera de la zona de res Desconectar el cable de ali No operar con panel abierto o

WARNING
Spanish

piracin. Mantenga la cabeza fuera de los humos. Utilice ventilacin o aspiracin para gases.
Gardez la tte lcart des fumes. Utilisez un ventilateur ou un aspira-

mentacin de poder de la mquina antes de iniciar cualquier servicio.

guardas quitadas.

AVISO DE PRECAUCION
French

Dbranchez le courant avant lentre-

Noprez pas avec les panneaux

tien.

teur pour ter les fumes des zones de travail.

Vermeiden Sie das Einatmen von Strom vor Wartungsarbeiten

ouverts ou avec les dispositifs de protection enlevs.

ATTENTION
German

Anlage nie ohne Schutzgehuse

Schweibrauch! Sorgen Sie fr gute Be- und Entlftung des Arbeitsplatzes!

Mantenha seu rosto da fumaa. Use ventilao e exhausto para

abschalten! (Netzstrom vllig ffnen; Maschine anhalten!)

oder Innenschutzverkleidung in Betrieb setzen!

WARNUNG
Portuguese

No opere com as tampas removidas. Desligue a corrente antes de fazer

Mantenha-se afastado das partes

moventes.
No opere com os paineis abertos

remover fumo da zona respiratria.

servio. No toque as partes eltricas nuas.

ATENO
Japanese

ou guardas removidas.

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS PRTICAS DE SEGURANA DO EMPREGADOR.

 World's Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com