Tomahawk 1000 User Manual

PROCEDURE RECOMMENDATIONS
When properly used, plasma arc cutting is a very eco-
nomical 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 ver-
tical 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
DRAG thru 1/16"
Standoff
1/16” Standoff
B-7
OPERATION
B-7
• 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.
TOMAHAWK™ 1000
Applications:
Removing weld imperfections – cracks, porosity, inclu-
sions, etc.
Back gouging for welding preparation
Removal of temporary fit up methods – tack welds,
bracketing, etc.
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.
PILOT ARC DISCUSSION
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 inter-
mittently. 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 fre-
quency starting. When the pilot arc is started, a slight
impulse will be felt in the torch handle. This occur-
rence is normal and is the mechanism which starts the
plasma arc. This impulse can also be used to help
troubleshoot a "no start" condition.
ELECTRIC SHOCK CAN KILL.
• Turn off machine at the disconnect
switch on the rear of the machine
before tightening, cleaning or
replacing consumables.
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WARNING

Tomahawk 1000 Specifications

General

Output Current Range	20 - 1000 A
Input Amperage at Rated Output	45 A
Rated Output	1000 A
Duty Cycle	60%
Protection Class	IP23

Summary

SAFETY

Electric Shock Hazards

Details risks of electric shock and precautions for safe operation.

Fumes and Gases Hazards

Explains dangers of fumes and gases produced during operation.

Arc Ray Hazards

Warns about the dangers of arc rays and necessary protection.

Cutting Sparks and Fire Hazards

Alerts to fire and explosion risks from cutting sparks.

Cylinder Explosion Hazards

Covers risks associated with compressed gas cylinders.

Electrical Equipment Safety

Outlines safety measures for electrically powered equipment.

Plasma Arc Injury Hazards

Warns about potential injuries from the plasma arc.

Electric and Magnetic Fields (EMF)

Discusses potential health effects of EMF and mitigation.

INSTALLATION

Technical Specifications

Provides detailed technical specifications for the TOMAHAWK 1000 plasma cutter.

Safety Precautions During Installation

Lists essential safety warnings and guidelines for installation procedures.

Input Electrical Connections

Details how to connect the machine to the electrical power supply.

Engine Driven Generator Operation

Explains conditions for operating the machine with engine driven generators.

Gas Input Connections

Describes requirements for supplying compressed air or nitrogen.

Output Connections

Details how to connect the torch and work clamp.

OPERATION

Safety Precautions During Operation

Reinforces safety guidelines relevant to operating the plasma cutter.

Machine Description and Features

Provides an overview of the TOMAHAWK 1000's capabilities and features.

Preheat Temperature Requirements

Advises on preheat temperature requirements for specific materials.

Cutting Capability and Duty Cycle

Details the cutting capacity and duty cycle of the machine.

Consumable Life and Replacement

Discusses the expected lifespan of torch consumables and replacement.

Controls and Settings Overview

Explains the function of various controls and indicators on the front panel.

Performing the Cutting Process

Guides on how to perform the plasma cutting process.

Performing the Gouging Process

Explains the plasma gouging process and technique.

Torch Part Configurations

Illustrates different torch setups for cutting and gouging.

ACCESSORIES

General Options and Accessories

Lists available optional accessories for the plasma cutter.

Available Torches

Details available replacement or optional plasma torches.

Expendable Parts Information

Refers to consumable parts needed for operation.

MAINTENANCE

Routine Maintenance Procedures

Outlines regular cleaning and inspection tasks for the machine.

Periodic Maintenance Tasks

Covers tasks performed at less frequent intervals.

Thermal Protection System

Explains the machine's thermal protection system and indicators.

TROUBLESHOOTING

Guide to Troubleshooting

Provides instructions on how to effectively use the troubleshooting section.

Status Board Indicator Meanings

Explains the meaning of various LED indicators on the machine.

Error Condition Identification

Details specific error conditions and their resolutions.

DIAGRAMS

Wiring Diagram Overview

Presents the electrical wiring schematic for the machine.