IM2014rev10 ENG
IM2014rev10 ENG
IM2014rev10 ENG
06/2023
REV10
OPERATOR’S MANUAL
ENGLISH
Model Name:
………………...…………………………….…………………………………………………………………………………………..
Code & Serial number:
………………….……………………………………………….. …………………………………………………….……………..
Date & Where Purchased:
…………………………………………………………………... ……………………….…………………………………………..
ENGLISH INDEX
Technical Specifications...............................................................................................................................................................1
ECO design information ...............................................................................................................................................................2
Electromagnetic Compatibility (EMC) ..........................................................................................................................................4
Safety............................................................................................................................................................................................5
Installation and Operator Instructions ..........................................................................................................................................7
WEEE .........................................................................................................................................................................................12
Spare Parts.................................................................................................................................................................................12
Authorized Service Shops Location ...........................................................................................................................................12
Electrical Schematic ...................................................................................................................................................................12
English I English
Technical Specifications
NAME INDEX
TOMAHAWK® 1025 K12048-1
TOMAHAWK® 1538 K12039-1
INPUT
Input Voltage Input Power at Rated Output EMC Class Frequency
4.3kW @ 100% Duty Cycle
TH1025
400V ±15% 7.1kW @ 40% Duty Cycle
A 50/60Hz
Three Phase 7.1kW @ 100% Duty Cycle
TH1538
13.7kW @ 40% Duty Cycle
RATED OUTPUT AT 40°C
Duty Cycle (Based on a
Output Current Output Voltage
10 min. period)
100% 40A 96VDC
TH1025 60% 50A 100VDC
40% 60A 104VDC
100% 60A 104VDC
TH1538 60% 85A 114VDC
40% 100A 120VDC
OUTPUT RANGE
Cutting Current Range Maximum Open Circuit Voltage Pilot Arc Current
TH1025 20 - 60A 320VDC 20A
TH1538 20 - 100A 320VDC 20A
COMPRESSED AIR or GAS
Required Flow Rate Required Inlet Pressure
TH1025 130 ±20% l/min @ 5.5bar
6.0bar ÷ 7.5bar
TH1538 280 ±20% l/min @ 5.5bar
RECOMMENDED INPUT CABLE AND FUSE SIZES
Fuse (delayed) or Circuit Breaker
Input Power Cable
(“D” characteristic) Size
TH1025 20A 4 x 2.5mm2
TH1538 32A 4 x 4mm2
PHYSICAL DIMENSIONS
Height Width Length Weight
TH1025 389mm 247mm 510mm 22kg
TH1538 455mm 301mm 640mm 34kg
OTHERS
Protection Rating Operating Temperature Storage Temperature
IP23 -10°C to +40°C -25°C to +55°C
English 1 English
ECO design information
The equipment has been designed in order to be compliant with the Directive 2009/125/EC and the Regulation
2019/1784/EU.
IDLE STATE
Condition Presence
MIG mode
TIG mode
STICK mode
After 30 minutes of non-working
Fan off X
The value of efficiency and consumption in idle state have been measured by method and conditions defined in the product
standard EN 60974-1:20XX.
Manufacturer’s name, product name, code number, product number, serial number and date of production can be read from
rating plate.
1 XXXXXXX 2
XXXXXXXXXX
3 Code: XXXXX XXXXXX-X 4
S/N: P1YYMMXXXXX
P1 YY MM XXXXX
5A 5B 5C 5D
Where:
1- Manufacturer name and address
2- Product name
3- Code number
4- Product number
5- Serial number
5A- country of production
5B- year of production
5C- month of production
5D- progressive number different for each machine
English 2 English
Typical gas usage for MIG/MAG equipment:
Wire DC electrode positive
Wire Feeding Gas flow
Material type diameter Current Voltage Shielding Gas
[m/min] [l/min]
[mm] [A] [V]
Carbon, low
0,9 ÷ 1,1 95 ÷ 200 18 ÷ 22 3,5 – 6,5 Ar 75%, CO2 25% 12
alloy steel
Aluminium 0,8 ÷ 1,6 90 ÷ 240 18 ÷ 26 5,5 – 9,5 Argon 14 ÷ 19
Austenic Ar 98%, O2 2% /
0,8 ÷ 1,6 85 ÷ 300 21 ÷ 28 3-7 14 ÷ 16
stainless steel He 90%, Ar 7,5% CO2 2,5%
Copper alloy 0,9 ÷ 1,6 175 ÷ 385 23 ÷ 26 6 - 11 Argon 12 ÷ 16
Magnesium 1,6 ÷ 2,4 70 ÷ 335 16 ÷ 26 4 - 15 Argon 24 ÷ 28
Tig Process:
In TIG welding process, gas usage depends on cross-sectional area of the nozzle. For commonly used torches:
Notice: Excessive flow rates causes turbulence in the gas stream which may aspirate atmospheric contamination into the
welding pool.
Notice: A cross wind or draft moving can disrupt the shielding gas coverage, in the interest of saving of protective gas use
screen to block air flow.
End of life
At end of life of product, it has to be disposal for recycling in accordance with Directive 2012/19/EU (WEEE), information
about the dismantling of product and Critical Raw Material (CRM) present in the product, can be found at
https://www.lincolnelectric.com/en-gb/support/Pages/operator-manuals-eu.aspx.
English 3 English
Electromagnetic Compatibility (EMC)
01/11
This machine has been designed in accordance with all relevant directives and standards. However, it may still generate
electromagnetic disturbances that can affect other systems like telecommunications (telephone, radio, and television) or
other safety systems. These disturbances can cause safety problems in the affected systems. Read and understand this
section to eliminate or reduce the amount of electromagnetic disturbance generated by this machine.
This machine has been designed to operate in an industrial area. The operator must install and operate this
equipment as described in this manual. If any electromagnetic disturbances are detected the operator must put
in place corrective actions to eliminate these disturbances with, if necessary, assistance from Lincoln Electric.
This equipment does not comply with IEC 61000-3-12. If it is connected to a public low-voltage system, it is
responsibility of the installer or user of the equipment to ensure, by consultation with the distribution network operator if
necessary, that the equipment may be connected.
Before installing the machine, the operator must check the work area for any devices that may malfunction because of
electromagnetic disturbances. Consider the following.
Input and output cables, control cables, and telephone cables that are in or adjacent to the work area and the machine.
Radio and/or television transmitters and receivers. Computers or computer controlled equipment.
Safety and control equipment for industrial processes. Equipment for calibration and measurement.
Personal medical devices like pacemakers and hearing aids.
Check the electromagnetic immunity for equipment operating in or near the work area. The operator must be sure that
all equipment in the area is compatible. This may require additional protection measures.
The dimensions of the work area to consider will depend on the construction of the area and other activities that are
taking place.
Consider the following guidelines to reduce electromagnetic emissions from the machine.
Connect the machine to the input supply according to this manual. If disturbances occur if may be necessary to take
additional precautions such as filtering the input supply.
The output cables should be kept as short as possible and should be positioned together. If possible connect the work
piece to ground in order to reduce the electromagnetic emissions. The operator must check that connecting the work
piece to ground does not cause problems or unsafe operating conditions for personnel and equipment.
Shielding of cables in the work area can reduce electromagnetic emissions. This may be necessary for special
applications.
WARNING
The Class A equipment is not intended for use in residential locations where the electrical power is provided by the public
low-voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations,
due to conducted as well as radio-frequency disturbances.
English 4 English
Safety
01/11
WARNING
This equipment must be used by qualified personnel. Be sure that all installation, operation, maintenance and repair
procedures are performed only by qualified person. Read and understand this manual before operating this equipment.
Failure to follow the instructions in this manual could cause serious personal injury, loss of life, or damage to this equipment.
Read and understand the following explanations of the warning symbols. Lincoln Electric is not responsible for damages
caused by improper installation, improper care or abnormal operation.
WARNING: This symbol indicates that instructions must be followed to avoid serious personal injury, loss
of life, or damage to this equipment. Protect yourself and others from possible serious injury or death.
READ AND UNDERSTAND INSTRUCTIONS: Read and understand this manual before operating this
equipment. Plasma cutting or gouging can be hazardous. Failure to follow the instructions in this manual
could cause serious personal injury, loss of life, or damage to this equipment.
ELECTRICALLY POWERED EQUIPMENT: Turn off input power using the disconnect switch at the fuse
box before working on this equipment. Ground this equipment in accordance with local electrical
regulations.
ELECTRIC AND MAGNETIC FIELDS MAY BE DANGEROUS: Electric current flowing through any
conductor creates electric and magnetic fields (EMF). EMF fields may interfere with some pacemakers,
and welders having a pacemaker shall consult their physician before operating this equipment.
ARTIFICIAL OPTICAL RADIATION: According with the requirements in 2006/25/EC Directive and
EN 12198 Standard, the equipment is a category 2. It makes mandatory the adoption of Personal
Protective Equipments (PPE) having filter with a protection degree up to a maximum of 15, as required by
EN169 Standard.
WORK MATERIALS CAN BURN: Cutting generates a large amount of heat. Hot surfaces and materials in
work area can cause serious burns. Use gloves and pliers when touching or moving materials in the work
area.
EQUIPMENT WEIGHT OVER 30kg: Move this equipment with care and with the help of another person.
Lifting may be dangerous for your physical health.
CYLINDER MAY EXPLODE IF DAMAGED: Use only compressed gas cylinders containing the correct
shielding gas for the process used and properly operating regulators designed for the gas and pressure
used. Always keep cylinders in an upright position securely chained to a fixed support. Do not move or
transport gas cylinders with the protection cap removed. Do not allow the torch, work clamp or any other
electrically live part to touch a gas cylinder. Gas cylinders must be located away from areas where they
may be subjected to physical damage or the cutting process including sparks and heat sources.
Cutting sparks can cause explosion or fire. Keep
flammables away from cutting. Do not cut near
flammables. Have a fire extinguisher nearby, and have a
watch person ready to use it. Do not cut on drums or any
closed container.
English 5 English
The plasma arc can cause injury and burns. Keep your
body away from nozzle and plasma arc. Turn off power
before disassembling torch. Do not grip material near
cutting path. Wear complete body protection.
Arc rays can burn eyes and injure skin. Wear hat and
safety glasses. Use ear protection and button shirt collar.
Use welding helmet with correct shade of filter. Wear
complete body protection.
SAFETY MARK: This equipment is suitable for supplying power for cutting operations carried out in an
environment with increased hazard of electric shock.
The manufacturer reserves the right to make changes and/or improvements in design without upgrade at the same time the
operator’s manual.
English 6 English
Installation and Operator Instructions
Read this entire section before installation or operation of It is important to check these conditions because many
the machine. engine driven generators produce high voltage spikes.
Operation of this machine on engine driven generators not
Location and Environment conforming to these conditions is not recommended and
This machine can operate in harsh environments. may damage the machine.
However, it is important that simple preventative
measures are followed to assure long life and reliable Output Connections
operation:
Do not place or operate this machine on a surface with WARNING
an incline greater than 15° from horizontal. Use ONLY the torch supplied with this machine. For a
Do not use this machine for pipe thawing. replacement refer to the Maintenance section of this
This machine must be located where there is free manual.
circulation of clean air without restrictions for air
movement to and from the air vents. Do not cover the WARNING
machine with paper, cloth or rags when switched on. TORCH PROTECTION: The torch delivered with the
Dirt and dust that can be drawn into the machine power source is equipped with a safety device that
should be kept to a minimum. prevents the operator from accidental contact with
This machine has a protection rating of IP23. Keep it electrically live parts.
dry when possible and do not place it on wet ground
or in puddles. WARNING
Locate the machine away from radio controlled Always turn OFF the machine when working on the torch.
machinery. Normal operation may adversely affect the
operation of nearby radio controlled machinery, which WARNING
may result in injury or equipment damage. Read the Do not remove the work clamp during cutting, plasma
section on electromagnetic compatibility in this cutting generates high voltages that can kill.
manual.
Do not operate in areas with an ambient temperature WARNING
greater than 40°C. Open Circuit Voltage U0 > 100VDC. For more information
refer to the Technical Specification section.
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.
English 7 English
Controls and Operational Features screwed on the torch head (or in the
machine torch connector).
Machine Auto-Test:
When the machine is turned ON, an auto-test is executed; To restore the machine:
during this test all of the LEDs of the Commands Front Screw firmly the torch retaining cap (or
Panel lights up. If one or some LED remains OFF, contact the torch connector).
the nearest technical service center or Lincoln Electric and After the torch is restored, the machine
report the LED Status found on the machine Front Panel. cannot restart for about 5 seconds.
During this time the PIP LED blinks.
Front Panel Controls (Note: When the LED is blinking, if
Output Current Knob: another PIP error occours or if the
Potentiometer used to set the output Torch Trigger pushbutton is pressed
current used during cutting. Refer to the the machine returns to the error
Technical Specification section for more condition: PIP LED returns steady ON
information about the machine rated and the restoring procedure begins
current range. again).
When the PIP LED turns OFF the
Gas Purge: machine is ready to operate.
The Output Current Knob completely Primary Gas Pressure Gauge and
rotated counterclockwise enables the gas Regulator Knob:
purge function. Allow to regulate and monitoring the
Power ON/OFF LED: primary gas pressure.
It lights up when the machine is ON.
The inlet primary gas pressure is
Blinking LED: Mains out of range condition. TH1025 limited by this pressure regulator, set at
The machine is disabled: when the mains factory at 5.5bar. In case to adjust the
returns in the correct range, the machine gas pressure, put the machine in Purge
restart automatically. mode.
English 8 English
Error condition list Rear Panel Controls and Connections
If occurs, try to turn Off the machine, wait for a few A. Fan: This machine has a
seconds, then turn ON again. If the error remains, a F.A.N. (Fan As Needed)
maintenance is required. Please contact the nearest circuitry inside: the fan is
technical service center or Lincoln Electric and report the automatically turned ON or
LED Status found on the machine Front Panel. OFF. This feature reduces the
amount of dirt which can be
drawn inside the machine and
reduces power consumption.
On Blink Blink When the machine is turned
This occurs if after 4seconds the Pilot Arc ON the fan will turn ON. The
isn’t transfered to the workpiece. The fan will continue to run
machine stops the pilot arc to avoid whenever the torch trigger
overheating on the Torch Head. pushbutton is pressed. If the
torch trigger pushbutton is released for more than five
Head Torch
To restore the machine: minutes, the fan will turn OFF.
Release the Torch Trigger pushbutton.
The blinking LEDs are now B. Power Switch: It turns ON / OFF the input power to
permanently ON. the machine.
Press again the release the Torch
Trigger pushbutton. C. Input cable: Connect it to the mains.
English 9 English
To start the selected process just press the torch button, Customer Assistance Policy
making sure you are not aiming the torch gas blow The business of The Lincoln Electric Company is
towards people or foreign objects. During the process it is manufacturing and selling high quality welding equipment,
possible to hold the torch away from the work piece for an consumables, and cutting equipment. Our challenge is to
extended period of time. meet the needs of our customers and to exceed their
expectations. On occasion, purchasers may ask Lincoln
Once the process is terminated releasing off the torch Electric for advice or information about their use of our
button will cause the plasma arc to be turned off; the gas products. We respond to our customers based on the best
flow will continue to allow the cooling down of the torch. information in our possession at that time. Lincoln Electric
The Post Flow time is proportional to the selected cutting is not in a position to warrant or guarantee such advice,
current and it is divided into 4 time ranges: and assumes no liability, with respect to such information
or advice. We expressly disclaim any warranty of any
Selected Cutting Current Post Flow Time kind, including any warranty of fitness for any customer’s
Less than 30A 15seconds particular purpose, with respect to such information or
advice. As a matter of practical consideration, we also
Between 30A and 40A 20seconds cannot assume any responsibility for updating or
Between 40A and 50A 25seconds correcting any such information or advice once it has
been given, nor does the provision of information or
Greater than 50A 30seconds
advice create, expand or alter any warranty with respect
to the sale of our products.
Maintenance Lincoln Electric is a responsive manufacturer, but the
selection and use of specific products sold by Lincoln
WARNING Electric is solely within the control of, and remains the sole
For any maintenance or repair operations it is responsibility of the customer. Many variables beyond the
recommended to contact the nearest technical service control of Lincoln Electric affect the results obtained in
center or Lincoln Electric. Maintenance or repairs applying these types of fabrication methods and service
performed by unauthorized service centers or personnel requirements.
will null and void the manufacturers warranty. Subject to Change – This information is accurate to the
best of our knowledge at the time of printing. Please refer
The frequency of the maintenance operations may vary in to www.lincolnelectric.com for any updated information.
accordance with the working environment. Any noticeable
damage should be reported immediately.
Check cables and connections integrity. Replace, if
necessary.
Regularly clean the torch head, check its consumables
and if necessary replace them.
WARNING
Refer to the torch instructions before changing or
servicing the torch.
WARNING
Do not open this machine and do not introduce anything
into its openings. Power supply must be disconnected
from the machine before maintenance and service. After
each repair, perform proper tests to check safety
requirements.
English 10 English
Cutting Speed
The cutting speed is a function of:
Thickness and of material to be cut.
Value of set current. The current setting affects the
quality of the cut edge.
Geometrical shape of the cut (whether straight or
curved).
TH1025 TH1538
Speed (cm/min.) Speed (cm/min.)
Current Current
STAINLESS MILD STAINLESS
Thickness (A) MILD STEEL ALUMINUM (A) ALUMINUM
STEEL STEEL STEEL
4 mm --- --- --- --- --- --- --- ---
6 mm --- --- --- --- --- --- --- ---
¼” --- --- --- --- --- --- --- ---
8 mm --- --- --- --- --- --- --- ---
10 mm 60 119 206 105 --- --- --- ---
½” 60 91 157 77 --- --- --- ---
15 mm 60 72 122 55 100A 180 223 147
¾” 60 48 75 40 100A 117 152 99
20 mm 60 43 65 36 100A 106 140 91
25 mm 60 26 36 17 100A 70 98 63
1” 60 25 35 16 100A 68 95 61
30 mm 60 --- 22 --- 100A 50 73 46
1¼” 60 --- 16 --- 100A 45 66 42
35 mm --- --- --- --- 100A 38 55 36
1½” --- --- --- --- 100A 32 48 31
English 11 English
WEEE
07/06
Spare Parts
12/05
First, read the Part List reading instructions above, then refer to the "Spare Part" manual supplied with the machine, that
contains a picture-descriptive part number cross-reference.
Electrical Schematic
Refer to the "Spare Part" manual supplied with the machine.
English 12 English