Lincoln Electric FlexCut 80 CCC Operator's Manual
  1. Manuals
  2. Brands
  3. Lincoln Electric Manuals
  4. Welding System
  5. FlexCut 80 CCC
  6. Operator's manual
Lincoln Electric FlexCut 80 CCC Operator's Manual

Lincoln Electric FlexCut 80 CCC Operator's Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
Operator's Manual
FlexCut
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)
IM10449-B
| Issue D ate Apr - 22
© Lincoln Global, Inc. All Rights Reserved.
80 CCC
®
For use with machines having Code Numbers:
12770, 12921, 13427

Advertisement

Table of Contents
loading

Related Manuals for Lincoln Electric FlexCut 80 CCC

Summary of Contents for Lincoln Electric FlexCut 80 CCC

  • Page 1 Operator’s Manual FlexCut 80 CCC ® For use with machines having Code Numbers: 12770, 12921, 13427 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) IM10449-B | Issue D ate Apr - 22 ©...
  • Page 2 THANK YOU FOR SELECTING KEEP YOUR HEAD OUT OF THE FUMES. A QUALITY PRODUCT BY 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 flowing 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 FLEXCUT 80 CCC SAFETY ® SAFETY ELECTRIC SHOCK PREVENTION The system uses high open circuit voltages that can be fatal. Extreme care should be used when operating or General Precautions performing maintenance on the system. Only qualified personnel Whereas plasma cutting has been used safely for years, it does should service the system.
  • Page 7 FLEXCUT 80 CCC SAFETY ® FIRE PREVENTION HEALTH SUPPORT EQUIPMENT When using the system , it is necessary to exercise good The system creates electric and magnetic fields that judgment. While cutting, the arc produces sparks that could cause a may interfere with certain types of health support fire if they fall on flammable materials.
  • Page 8 FLEXCUT 80 CCC SAFETY ® 17. CGA booklet TB-3, Hose Line Flashback Arrestors, obtainable from Safety Standards Booklet Index the Compressed Gas Association, 1725 Jefferson Davis Highway, For further information concerning safety practices to be exercised Suite 1004, Arlington, VA 22202. with plasma arc cutting equipment, please refer to the following 18.

  • Page 9: Table Of Contents

    FLEXCUT 80 CCC ® Table Of Contents Page General Description ............................ Preheat Temperature For Plasma Cutting ....................6 Duty Cycle............................6 User Responsibility..........................6 Design Features And Advantages ......................6 Installation ..........................Section A Select Suitable Location........................A-1 Lifting ............................A-2 Stacking ............................A-2 Tilting ............................A-2 High Frequency Interference Protection ...................A-2 Input Connection..........................A-2 Machine Grounding..........................A-2 Input Plug Installation ........................A-3...

  • Page 10: General Description

    FLEXCUT 80 CCC ® GENERAL DESCRIPTION USER RESPONSIBILITY Because design, fabrication, erection and cutting variables affect the results obtained in applying this type of information, the serviceability ® The FLEXCUT 80 CCC is a constant current, continuous control of a product or structure is the responsibility of the user. Variation plasma cutting power source.

  • Page 11: Installation

    FLEXCUT 80 CCC INSTALLATION ® TECHNICAL SPECIFICATIONS - K4809-1 FLEXCUT 80 CCC ® INPUT - SINGLE PHASE/THREE PHASE/ 50 / 60 HERTZ Input Voltage +/- 10% Input Amperes @ Rated Output Circuit Breaker (Delay Type) 80% Duty Cycle 80 Amps 200V/208V/1/50/60 100% Duty Cycle 60 Amps...

  • Page 12: Select Suitable Location

    FLEXCUT 80 CCC INSTALLATION ® Read entire Installation Section before installing the HIGH FREQUENCY INTERFERENCE PROTECTION FLEXCUT ® 80 CCC . The FLEXCUT ® 80 CCC employs a touch start mechanism for arc initiation which eliminates high frequency emissions from the SAFETY PRECAUTIONS machine as compared with spark gap and solid state type high frequency generators.

  • Page 13: Input Plug Installation

    • The AC waveform frequency is between 45 and 65 Hz. the connection diagrams. Failure to do so may result in bodily injure or death. Lincoln Electric Vantage ® and Ranger ® engine drives meet these specifications.

  • Page 14: Connecting The Gas Supply

    14 ipm 1-1/4 in. 9 ipm Gouge Capacity - Mild Steel Metal Removal Rate - 80 Amps 19.08 lbs/hr Maximum cut speeds are based on results obtained from Lincoln Electric’s laboratory testing. Different cutting applications may alter the actual cutting speed.

  • Page 15: Operation

    FLEXCUT 80 CCC OPERATION ® OPERATION GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL SAFETY PRECAUTIONS WARNING OR CAUTION WARNING ELECTRIC SHOCK can kill. INPUT VOLTAGE • Do not touch electrically live parts or electrode with skin or wet OUTPUT ON clothing.

  • Page 16: Controls And Settings

    FLEXCUT 80 CCC OPERATION ® CONTROLS AND SETTINGS 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 FIGURE B.2 FLEXCUT ® 80 CCC front command panel.
  • Page 17 FLEXCUT 80 CCC OPERATION ® 9. Torch Connection: Connect handheld or machine torch. 10. Work Connection: Connect cable with work clamp. 11. Remote Connection (14-pin amphenol): Allows access to Arc Start trigger, Arc Initiated contact and raw Arc Voltage. Items 12 thru 15 on the back of the FLEXCUT ®...

  • Page 18: Hand Cutting

    FLEXCUT 80 CCC OPERATION ® HAND CUTTING TORCH PART CONFIGURATIONS Different hand held torch configurations are available depending on the cutting or gouging application. Handle S28175-1 Head S28176-1 Insulation Kit S28176-4 Electrode KP4141-1 Swirl Ring KP4141-9 Standard Gouging Nozzle Gouge Nozzle 40A - KP4141-4 KP4141-18 (80A) 60A - KP4141-5...

  • Page 19: Hand Cutting Charts

    FLEXCUT 80 CCC OPERATION ® • Pierce the work piece by slowly lowering the torch onto the metal Hand Cutting Process at a 30º angle away from the operator. This will blow the dross The air plasma cutting process uses air or nitrogen as a cutting gas away from the torch tip.
  • Page 20 FLEXCUT 80 CCC OPERATION ® MILD STEEL CUT CHARTS - FLEXCUT 80; LC105 HAND TORCH *Above listed speeds provide best cut quality - best cut angle, least dross, best cut surface finish.
  • Page 21 FLEXCUT 80 CCC OPERATION ® STAINLESS STEEL CUT CHARTS - FLEXCUT 80; LC105 HAND TORCH *Above listed speeds provide best cut quality - best cut angle, least dross, best cut surface finish.
  • Page 22 FLEXCUT 80 CCC OPERATION ® ALUMINUM CUT CHARTS - FLEXCUT 80; LC105 HAND TORCH WARNING When using a water table and cutting aluminum under water or with water touching the underside at the aluminum plate, hydrogen gas is produced. This hydrogen gas may collect under the plate and explode during the cutting process.
  • Page 23 FLEXCUT 80 CCC OPERATION ® Gouging Process Gouging is a process used to remove material without cutting entirely WARNING ® through the workpiece. The FLEXCUT 80 CCC has the capability of performing plasma gouging with the proper consumables attached to ELECTRIC SHOCK CAN KILL.

  • Page 24: Mechanized Cutting

    FLEXCUT 80 CCC OPERATION ® MECHANIZED CUTTING Removing the Torch Consumables Mechanized Torch Installation To remove the torch consumables, perform the following steps: ® It is recommended that the FLEXCUT 80 CCC mechanized torch be installed on a positioner with an arc voltage control capable of 1.
  • Page 25 FLEXCUT 80 CCC OPERATION ® Making a Cut Machine Interface Setting up a Cut The FLEXCUT ® 80 CCC comes standard with a machine interface. Interface signals provided include: arc start, arc initiated, and arc Use the following procedure to make a cut with the voltage.

  • Page 26: Mechanized Cutting Charts

    FLEXCUT 80 CCC OPERATION ® MECHANIZED 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 27 FLEXCUT 80 CCC OPERATION ® PRECISION CUT CONSUMABLES SHIELD RETAINING CAP NOZZLE SWIRL RING ELECTRODE LC105M TORCH BK12849-12 BK12849-9 BODY BK12849-10 BK12849-11 BK12849-1 Precision Cut Standard Speed Mild Steel Pierce Cu ng Op mum Travel Pierce Edge Material Thickness Kerf Width Height Height Delay...
  • Page 28 FLEXCUT 80 CCC OPERATION ® 40 AMP MECHANIZED SHIELD CONSUMABLES SHIELD SWIRL RING ELECTRODE LC105M TORCH RETAINING CAP NOZZLE BK12849-13 BODY BK12849-10 BK12849-4 BK12849-9 BK12849-1 Higher cut speeds can be achieved at 45 amps with a reduction in nozzle life. WARNING When using a water table and cutting aluminum under water or with water touching the underside at the aluminum plate, hydrogen gas is...
  • Page 29 FLEXCUT 80 CCC OPERATION ® 60 AMP MECHANIZED SHIELD CONSUMABLES SHIELD RETAINING CAP NOZZLE SWIRL RING ELECTRODE LC105M TORCH BK12849-2 BK12849-9 BK12849-1 BODY BK12849-10 BK12849-5 WARNING When using a water table and cutting aluminum under water or with water touching the underside at the aluminum plate, hydrogen gas is produced.
  • Page 30 FLEXCUT 80 CCC OPERATION ® 80 AMP MECHANIZED SHIELD CONSUMABLES SHIELD RETAINING CAP NOZZLE SWIRL RING ELECTRODE LC105M TORCH BK12849-2 BK12849-10 BK12849-9 BK12849-1 BODY BK12849-6 WARNING When using a water table and cutting aluminum under water or with water touching the underside at the aluminum plate, hydrogen gas is produced.

  • Page 31: Consumable Life

    FLEXCUT 80 CCC OPERATION ® CONSUMABLE LIFE CUT QUALITY Use the following guidelines to maximize consumable parts life: Before the optimum cutting condition can be achieved on a particular material type and thickness, the machine operator must have a ® 1.
  • Page 32 FLEXCUT 80 CCC OPERATION ® INSPECTION OF CONSUMABLE PARTS When the cut quality is not satisfactory, use the following guidelines for determining which consumable parts need to be changed. Inspect all parts for dirt or debrisand clean as necessary. PART INSPECT FOR CORRECTIVE ACTION SHIELD CAP...
  • Page 33 FLEXCUT 80 CCC OPERATION ® Suggestions for Extra Utility from the FLEXCUT 80 CCC System: ® WARNING ELECTRIC SHOCK CAN KILL. • Turn off machine at the disconnect switch on the rear of th machine before tightening, cleaning or replacing consumables. CONSUMABLE LIFE 1.

  • Page 34: Accessing Divided Arc Voltage

    FLEXCUT 80 CCC OPERATION ® ACCESSING DIVIDED ARC VOLTAGE The Flexcut® 80 CCC is factory set to provide raw arc voltage through the 14 pin CNC Connector (see arc voltage on page B-6). 5. Set the switch as follows to get the desired divided voltage: 30:1, 40:1, or 50:1 instead of raw arc voltage by following these steps: 20:1...

  • Page 35: Options/Accessories

    FLEXCUT 80 CCC ACCESSORIES ® OPTIONS/ACCESSORIES The following options/accessories are available for your FlexCut™ 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: K2849-1 LC105 Handheld Plasma Torch 25' (7.5m)

  • Page 36: Maintenance

    FLEXCUT 80 CCC MAINTENANCE ® MAINTENANCE MONTHLY PROCEDURES POWER SUPPLY WARNING 1. Using clean, dry, compressed air, blow out all accumulated dust ELECTRIC SHOCK CAN KILL. inside the machine. Be sure to clean all printed circuit boards, • Have an electrician install and service heatsinks, power switch, and fan.

  • Page 37: Troubleshooting

    TROUBLESHOOTING 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.
  • Page 38 FLEXCUT 80 CCC TROUBLESHOOTING ® Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENTS COURSE OF ACTION Input circuit breaker trips repeatedly. 1. Verify that the input circuit protection is properly sized per the voltage being sup- plied.
  • Page 39 FLEXCUT 80 CCC TROUBLESHOOTING ® Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENTS COURSE OF ACTION The FLEXCUT ® 80 CCC powers up properly 1. Turn the output knob to purge zone on but there is no response when the trigger is the front of the FLEXCUT ®...
  • Page 40 FLEXCUT 80 CCC TROUBLESHOOTING ® Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENTS COURSE OF ACTION When the trigger is pulled air begins to flow, 1. Check the torch consumables to be sure but there is no pilot arc after at least 3 they are not dirty or greasy, and are in seconds.
  • Page 41 FLEXCUT 80 CCC TROUBLESHOOTING ® Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENTS COURSE OF ACTION Pilot arc starts but will not transfer when 1. Check work lead connection for clean, brought near work. secure connection.
  • Page 42 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.
  • Page 43 FLEXCUT 80 CCC TROUBLESHOOTING ® Observe all Safety Guidelines detailed throughout this manual Error condition list (Green LED) (Yellow LED) (Yellow LED) No pilot arc established 1. The machine output is triggered. During this period the machine will attempt to start the pilot arc 4 times.
  • Page 44 FLEXCUT 80 CCC DIAGRAMS ®...
  • Page 45 FLEXCUT 80 CCC DIAGRAMS ®...
  • Page 46 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 No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el AVISO DE bajo carga con la piel o ropa moja-...
  • Page 47 Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or Use ventilation or exhaust to guards off. WARNING remove fumes from breathing zone. Spanish Los humos fuera de la zona de res- Desconectar el cable de ali- No operar con panel abierto o AVISO DE...
  • Page 48 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...

This manual is also suitable for:

127701292113427

Table of Contents