Lincoln Electric FlexCut 200 CE Operator's Manual
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Lincoln Electric FlexCut 200 CE Operator's Manual

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Operator's Manual
FlexCut
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Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM10485-A
| Issue D ate Jul-22
© Lincoln Global, Inc. All Rights Reserved.
200 CE
®
For use with machines having Code Numbers:
12829

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  • Page 1 Operator’s Manual FlexCut 200 CE ® For use with machines having Code Numbers: 12829 Register your machine: www.lincolnelectric.com/register Authorized Service and Distributor Locator: www.lincolnelectric.com/locator Save for future reference Date Purchased Code: (ex: 10859) Serial: (ex: U1060512345) IM10485-A | Issue D ate Jul-22 ©...
  • Page 2 THANK YOU FOR SELECTING A QUALITY PRODUCT BY KEEP YOUR HEAD OUT OF THE FUMES. DON’T get too close to the arc. LINCOLN ELEC TRIC. Use corrective lenses if necessary to stay a reasonable distance away from the arc. READ and obey the Safety Data PLEASE EXAMINE CARTON AND EQUIPMENT FOR Sheet (SDS) and the warning label DAMAGE IMMEDIATELY...
  • Page 3 P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2. A Free copy of “Arc Welding Safety” booklet E205 2.a. Electric current owing through any conductor is available from the Lincoln Electric Company, 22801 causes localized Electric and Magnetic Fields (EMF). St. Clair Avenue, Cleveland, Ohio 44117-1199.
  • Page 4 SAFETY ELECTRIC SHOCK ARC RAYS CAN BURN. CAN KILL. 3.a. The electrode and work (or ground) circuits are 4.a. Use a shield with the proper filter and cover plates to protect your electrically “hot” when the welder is on. Do eyes from sparks and the rays of the arc when welding or not touch these “hot”...
  • Page 5 SAFETY WELDING AND CUTTING CYLINDER MAY EXPLODE IF SPARKS CAN CAUSE DAMAGED. FIRE OR EXPLOSION. 7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used 6.a. Remove fire hazards from the welding area. If and properly operating regulators designed for this is not possible, cover them to prevent the welding sparks the gas and pressure used.
  • Page 6 Typical gas usage for the Flexcut equipment: The Flexcut 200 CE uses an external Air Compressor, so there are no typical gas flow rates for this product. ECO design information ECO design information...
  • Page 7 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: www.lincolnelectriceurope.com Flexcut 200 CE Item Component...
  • Page 8 ® FlexCut 200 CE SAFETY SAFETY General Precautions ELECTRIC SHOCK PREVENTION Whereas plasma cutting has been used safely for years, it does require certain precautions to ensure the safety of the operator The system uses high open circuit voltages that can and other people around the equipment.
  • Page 9 ® FlexCut 200 CE SAFETY FIRE PREVENTION HEALTH SUPPORT EQUIPMENT When using the system , it is necessary to exercise good The system creates electric and magnetic fields judgment. While cutting, the arc produces sparks that could cause that may interfere with certain types of health a fire if they fall on flammable materials.
  • Page 10 ® FlexCut 200 CE SAFETY Safety Standards Booklet Index 17. CGA booklet TB-3, Hose Line Flashback Arrestors, obtainable from the Compressed Gas Association, 1725 Jefferson Davis For further information concerning safety practices to be exercised Highway, Suite 1004, Arlington, VA 22202. with plasma arc cutting equipment, please refer to the following 18.
  • Page 11 60974-10 Electromagnetic Compatibility (EMC) Product Standard for METHODS OF REDUCING EMISSIONS Arc Welding Equipment. It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use. Welding equipment should be connected to the public supply system according to the manufacturer’s recommendations.

  • Page 12: Table Of Contents

    ® FlexCut 200 CE INSTALLATION ...........................SECTION A ® TECHNICAL SPECIFICATIONS -K4812-2 FLEXCUT 200 CE..............A-1 GENERAL DESCRIPTION...........................A-2 RECOMMENDED PROCESSES ........................A-2 PROCESS LIMITATIONS ...........................A-2 EQUIPMENT LIMITATIONS........................A-2 USER RESPONSIBILITY ..........................A-2 DESIGN FEATURES AND ADVANTAGES ....................A-2 INSTALLATION ............................A-3 LOCATION AND VENTILATION FOR COOLING....................A-3 LIFTING ............................A-3 STACKING ............................A-3 TILTING...

  • Page 13: Installation

    ® FlexCut 200 CE INSTALLATION TECHNICAL SPECIFICATIONS - K4812-2 FlexCut 200 CE ® Cord and Fuse Sizes based upon the U.S. National Electric Code and maximum output Also called 'inverse time' or 'thermal/magnetic' circuit breakers; circuit breakers that have a delay in tripping action that decreases as the magni- tude of RATED OUTPUT AT 40°...

  • Page 14: General Description

    The FlexCut 200 CE design makes plasma cutting uncom- ® primarily designed to interface with Lincoln Electric Cutting plicated. This list of design features and advantages will help you Systems tables and pipe cutters. However, it can also be utilized...

  • Page 15: Installation

    ® FlexCut 200 CE INSTALLATION READ ENTIRE INSTALLATION SECTION BEFORE ® INSTALLING THE FlexCut 200 CE ENVIRONMENTAL LIMITATIONS ® The FlexCut 200 CE is IP23 rated for use in an outdoor INSTALLATION ® environment. The FlexCut 200 CE should not be subjected to falling water during use nor should any parts of it be submerged in water or snow.

  • Page 16: Input Connection

    ® FlexCut 200 CE INSTALLATION INPUT CONNECTION INPUT FUSE AND SUPPLY WIRE CONSIDERATIONS Refer to the Specification Section for recommended fuse, wire WARNING sizes, and type of copper wires. Fuse the input circuit with the recommended super lag fuses or delay type breakers (also called ELECTRIC SHOCK CAN KILL.

  • Page 17: Gas Supply Requirements

    ® FlexCut 200 CE INSTALLATION GAS SUPPLY REQUIREMENTS SYSTEM OVERVIEW ® The FlexCut 200 CE power source is designed to be a part of a Supply the FlexCut® 200 with clean, dry, oil-free compressed air, ® modular cutting system typically controlled by a Torchmate HMI.

  • Page 18: Connection Diagram

    ® FlexCut 200 CE INSTALLATION CONNECTION DIAGRAM...
  • Page 19 ® FlexCut 200 CE INSTALLATION CONNECTION DIAGRAM...
  • Page 20 ® FlexCut 200 CE INSTALLATION CONNECTION DIAGRAM...
  • Page 21 ® FlexCut 200 CE INSTALLATION CONNECTION DIAGRAM...
  • Page 22 ® FlexCut 200 CE INSTALLATION CONNECTION DIAGRAM A-10...

  • Page 23: Power Supply Output Connections

    ® Connection Between the FlexCut 200 CE and HMI FlexCut 200 CE is equipped with an 8P8C RJ45 style ethernet jack for this purpose. The receptacle is located on the rear panel of the machine. Note: Ethernet cables should not be routed with weld cables, wire drive control cables, or any other current carrying device that can create a fluctuating magnetic field.

  • Page 24: Operation

    ® FlexCut 200 CE OPERATION OPERATION POWER-UP SEQUENCE SAFETY PRECAUTIONS ® When power is applied to the FlexCut 200 CE the User Interface will initialize, during this time the system will purge plasma and shielding gas while circulating coolant for 30 seconds. This is normal and WARNING ®...

  • Page 25: Case Front Controls

    ® FlexCut 200 CE OPERATION CASE FRONT CONTROLS CASE BACK CONTROLS FIGURE B.1 FIGURE B.2 1. LCD Display: Shows available modes and real time 14. Shielding Gas Inlet (optional): Allows ability for independent parameters and system errors. air/gas to be connected for shield . 2.

  • Page 26: User Interface

    ® FlexCut 200 CE OPERATION USER INTERFACE Mode Select Screen Output Current Active Mode Icon Cutting The Active Mode Screen will display the following information: Press to Select Active Mode Icon- The currently selected mode icon will be displayed here. To select a new mode, press the HOME button and the desired mode, or utilize the HMI.
  • Page 27 ® FlexCut 200 CE OPERATION Settings Press both the home and purge buttons at the same time to enter or exit the settings menu. Options (turn the knob to scroll and press the knob to select): Reset Factory Settings – Use to Reset Factory Settings Language restore the machine back to the...

  • Page 28: Interface

    ® FlexCut 200 CE OPERATION MACHINE INTERFACE ACCESSING DIVIDED ARC VOLTAGE ® ® The FlexCut 200 comes standard with a machine interface. The FlexCut 200 is factory set to provide raw arc voltage through Interface signals provided include: Arc Start, Arc Initiated, the 14 pin CNC Connector.

  • Page 29: Cutting Charts

    ® FlexCut 200 CE OPERATION CUTTING CHARTS The cutting charts shown on the following pages are intended to give the operator the best starting point to use when making a cut on a particular material type and thickness. Small adjustments may have to be made to achieve the best cut.

  • Page 30: Selecting Consumables - Air Plasma / Air Shield

    ® FlexCut 200 CE OPERATION SELECTING CONSUMABLES - AIR PLASMA / AIR SHIELD Outer Retaining Shield Inner Nozzle Swirl Ring Electrode Torch Head Retaining Cap MS/AL 100A MS/SS/AL 150A MS/SS/AL 200A 200A SS/AL...
  • Page 31 ® FlexCut 200 CE OPERATION 50 Amps - Mild Steel Imperial* Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Pressure Voltage Speed Height Height Time Width Start (ga) (in) (psi) (psi) (ipm) (in) (in) (ms) (in) 26 ga 0.018 0.100 0.200...
  • Page 32 ® FlexCut 200 CE OPERATION 100 Amps - Mild Steel Imperial* Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Pressure Voltage Speed Height Height Time Width Start (ga) (in) (psi) (psi) (ipm) (in) (in) (ms) (in) 0.105 0.110 0.200 0.086...
  • Page 33 ® FlexCut 200 CE OPERATION 150 Amps - Mild Steel Imperial* Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Pressure Voltage Speed Height Height Time Width Start (ga) (in) (psi) (psi) (ipm) (in) (in) (ms) (in) 0.135 0.100 0.275 0.075...
  • Page 34 ® FlexCut 200 CE OPERATION 200 Amps - Mild Steel Imperial* Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Pressure Voltage Speed Height Height Time Width Start (ga) (in) (psi) (psi) (ipm) (in) (in) (ms) (in) 0.250 0.150 0.275 0.085...
  • Page 35 ® FlexCut 200 CE OPERATION 50 Amps - Stainless Steel Imperial Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Pressure Voltage Speed Height Height Time Width Start (ga) (in) (psi) (psi) (ipm) (in) (in) (ms) (in) 26 ga 0.018 0.040 0.100...
  • Page 36 ® FlexCut 200 CE OPERATION 100 Amps - Stainless Steel Imperial* Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Pressure Voltage Speed Height Height Time Width Start (ga) (in) (psi) (psi) (ipm) (in) (in) (ms) (in) 0.135 0.120 0.200 0.095...
  • Page 37 ® FlexCut 200 CE OPERATION 150 Amps - Stainless Steel Imperial* Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Pressure Voltage Speed Height Height Time Width Start (ga) (in) (psi) (psi) (ipm) (in) (in) (ms) (in) 3/16 0.188 0.140 0.225...
  • Page 38 ® FlexCut 200 CE OPERATION 200 Amps - Stainless Steel Imperial* Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Pressure Voltage Speed Height Height Time Width Start (ga) (in) (psi) (psi) (ipm) (in) (in) (ms) (in) 3/16 0.188 0.150 0.200...
  • Page 39 ® FlexCut 200 CE OPERATION 50 Amps - Aluminum Imperial Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Pressure Voltage Speed Height Height Time Width Start (ga) (in) (psi) (psi) (ipm) (in) (in) (ms) (in) 26 ga 0.018 24 ga 0.024...
  • Page 40 ® FlexCut 200 CE OPERATION 100 Amps - Aluminum Imperial* Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Pressure Voltage Speed Height Height Time Width Start (ga) (in) (psi) (psi) (ipm) (in) (in) (ms) (in) 12 ga 0.102 0.120 0.225...
  • Page 41 ® FlexCut 200 CE OPERATION 150 Amps - Aluminum Imperial* Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Pressure Voltage Speed Height Height Time Width Start (ga) (in) (psi) (psi) (ipm) (in) (in) (ms) (in) 3/16 0.188 0.120 0.250 0.115...
  • Page 42 ® FlexCut 200 CE OPERATION 200 Amps - Aluminum Imperial* Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Pressure Voltage Speed Height Height Time Width Start (ga) (in) (psi) (psi) (ipm) (in) (in) (ms) (in) 3/16 0.188 0.170 0.250 0.147...

  • Page 43: Selecting Consumables - Oxygen Plasma / Oxygen Or Air Shield

    ® FlexCut 200 CE OPERATION SELECTING CONSUMABLES - OXYGEN PLASMA / OXYGEN OR AIR SHIELD (50A) OXYGEN PLASMA / AIR SHIELD (100A, 150A, 200A) Outer Retaining Shield Inner Nozzle Swirl Ring Electrode Torch Head Retaining Cap 100A 150A 200A...
  • Page 44 ® FlexCut 200 CE OPERATION 50 Amps - Mild Steel - Oxygen Plasma / Oxygen or Air Shield Imperial Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Pressure Voltage Speed Height Height Time Width Start (ga) (in) (psi) (psi) (ipm)
  • Page 45 ® FlexCut 200 CE OPERATION 100 Amps - Mild Steel - Oxygen Plasma / Air Shield Imperial Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Pressure Voltage Speed Height Height Time Width Start (ga) (in) (psi) (psi) (ipm) (in) (in)
  • Page 46 ® FlexCut 200 CE OPERATION 150 Amps - Mild Steel - Oxygen Plasma / Air Shield Imperial Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Pressure Voltage Speed Height Height Time Width Start (ga) (in) (psi) (psi) (ipm) (in) (in)
  • Page 47 ® FlexCut 200 CE OPERATION 200 Amps - Mild Steel - Oxygen Plasma / Air Shield Imperial Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Pressure Voltage Speed Height Height Time Width Start (ga) (in) (psi) (psi) (ipm) (in) (in)

  • Page 48: Selecting Consumables - Air Plasma / Nitrogen Shield

    ® FlexCut 200 CE OPERATION SELECTING CONSUMABLES - AIR PLASMA / NITROGEN SHIELD Outer Retaining Shield Inner Nozzle Swirl Ring Electrode Torch Head Retaining Cap BK277122 100A SS/AL 150A SS/AL 200A SS/AL...
  • Page 49 ® FlexCut 200 CE OPERATION 50 Amps - Stainless Steel - Air Plasma / Nitrogen Shield Imperial Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Pressure Voltage Speed Height Height Time Width Start (ga) (in) (psi) (psi) (ipm) (in) (in)
  • Page 50 ® FlexCut 200 CE OPERATION 100 Amps - Stainless Steel - Air Plasma / Nitrogen Shield Imperial Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Pressure Voltage Speed Height Height Time Width Start (ga) (in) (psi) (psi) (ipm) (in) (in)
  • Page 51 ® FlexCut 200 CE OPERATION 150 Amps - Stainless Steel - Air Plasma / Nitrogen Shield Imperial Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Pressure Voltage Speed Height Height Time Width Start (ga) (in) (psi) (psi) (ipm) (in) (in)
  • Page 52 ® FlexCut 200 CE OPERATION 200 Amps - Stainless Steel - Air Plasma / Nitrogen Shield Imperial Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Pressure Voltage Speed Height Height Time Width Start (ga) (in) (psi) (psi) (ipm) (in) (in)
  • Page 53 ® FlexCut 200 CE OPERATION 50 Amps - Aluminum - Air Plasma / Nitrogen Shield Imperial Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Pressure Voltage Speed Height Height Time Width Start (ga) (in) (psi) (psi) (ipm) (in) (in) (ms)
  • Page 54 ® FlexCut 200 CE OPERATION 100 Amps - Aluminum - Air Plasma / Nitrogen Shield Imperial Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Pressure Voltage Speed Height Height Time Width Start (ga) (in) (psi) (psi) (ipm) (in) (in) (ms)
  • Page 55 ® FlexCut 200 CE OPERATION 150 Amps - Aluminum - Air Plasma / Nitrogen Shield Imperial Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Pressure Voltage Speed Height Height Time Width Start (ga) (in) (psi) (psi) (ipm) (in) (in) (ms)
  • Page 56 ® FlexCut 200 CE OPERATION 200 Amps - Aluminum - Air Plasma / Nitrogen Shield Imperial Plasma Shield Travel Cutting Pierce Pierce Kerf Edge Material Thickness Pressure Pressure Voltage Speed Height Height Time Width Start (ga) (in) (psi) (psi) (ipm) (in) (in) (ms)

  • Page 57: Options/Accessories

    ® FlexCut 200 CE ACCESSORIES OPTIONS/ACCESSORIES ® The following options/accessories are available for your FlexCut ® Plasma cutter from your local Lincoln Electric Distributor. COMMON EQUIPMENT PACKAGES ® K4812-2 FlexCut 200 CE K4816-1 FlexCool™ cooler K4817-1 FlexStart ® arc start console Control Cable (5 pin –...

  • Page 58: Maintenance

    ® FlexCut 200 CE MAINTENANCE MAINTENANCE GAS SUPPLY WARNING Check for signs of contamination in the gas supply lines. ELECTRIC SHOCK CAN KILL. • Have an electrician install and service this equipment. • Turn the input power off at the fuse box Drain filter bowl as needed.

  • Page 59: Troubleshooting

    ® FlexCut 200 CE TROUBLESHOOTING TROUBLESHOOTING USING THE STATUS LED TO TROUBLESHOOT HOW TO USE TROUBLESHOOTING GUIDE SYSTEM PROBLEMS WARNING Prior to cycling power to the system, check the power source LCD ® screen, the FlexCool 35 LED, FlexCut 200 CE LED and the FlexStart LED for errorsequences as noted below.
  • Page 60 ® FlexCut 200 CE TROUBLESHOOTING Possible Cause 0021 Pilot timeout error Recommended Course of Action In cut, mark, and grid modes, the pilot arc will only run for 5 seconds to prevent unnecessary consumable wear. Verify the correct torch to workpiece DESCRIPTION: height and that the work lead is connected and making a good electrical Transfer Failed...
  • Page 61 ® FlexCut 200 CE TROUBLESHOOTING Possible Cause 0006 Communication error between power board and control board. Recommended Course of Action Cycle power to the machine to see if the error clears. Otherwise a qualified technician must check communication between the power and control DESCRIPTION: boards.
  • Page 62 ® FlexCut 200 CE TROUBLE SHOOTING Possible Cause Recommended Course of Action DESCRIPTION: Possible Cause Recommended Course of Action DESCRIPTION: Possible Cause Recommended Course of Action DESCRIPTION: Possible Cause Recommended Course of Action DESCRIPTION:...
  • Page 63 ® FlexCut 200 CE TROUBLE SHOOTING Possible Cause Recommended Course of Action DESCRIPTION:...
  • Page 64 ® FlexCut 200 CE DIAGRAMS FRONT OF MACHINE J1-1 J1-2 J1-3 J1-4 J1-5 J1-6 J1-8 J23-3 J1-9 J23-4 J1-10 J23-9 J23-10 J1-11 J23-1 J1-12 J23-2 J1-13 J1-14 J23-7 J23-8 J1-16 J23-11 J23-6 J23-5 J28-1 J28-2 J28-3 J28-4 J28-5 J28-6 J28-8 J28-9 J28-10 J28-11...
  • Page 65 ® FlexCut 200 CE DIAGRAMS...
  • Page 66 ® FlexCut 200 CE DIAGRAMS...
  • Page 67 ® FlexCut 200 CE DIAGRAMS...
  • Page 68 ® FlexCut 200 CE DIAGRAMS...
  • Page 69 ® FlexCut 200 CE DIAGRAMS...
  • Page 72 Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. WARNING electrode with skin or wet clothing. Insulate yourself from work and ground. Spanish AVISO DE No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el bajo carga con la piel o ropa moja-...
  • Page 73 Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or WARNING Use ventilation or exhaust to guards off. remove fumes from breathing zone. Spanish Los humos fuera de la zona de res- AVISO DE Desconectar el cable de ali- No operar con panel abierto o...
  • Page 74 Lincoln Electric is a responsive manufacturer, but the de nition of speci cations, and the selection and use of speci c 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.

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