Lincoln Electric FlexCut 80 Operator's Manual
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Lincoln Electric FlexCut 80 Operator's Manual

12249, 12589
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Operator's Manual
FlexCut
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Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM10197-B
| Issue D ate Oct-16
© Lincoln Global, Inc. All Rights Reserved.
™
80
For use with machines having Code Numbers:
12249, 12589

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  • Page 1 Operator’s Manual FlexCut ™ For use with machines having Code Numbers: 12249, 12589 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) IM10197-B | Issue D ate Oct-16 ©...
  • 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 MAGNETIC FIELDS MAY W117.2-1974. A Free copy of “Arc Welding Safety” booklet BE DANGEROUS E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. 2.a. Electric current flowing through any conductor BE SURE THAT ALL INSTALLATION, OPERATION, causes localized Electric and Magnetic Fields (EMF).
  • Page 4 S FETY 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 S FETY 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: General Precautions

    FLEXCUT™ 80 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: Fire Prevention

    FLEXCUT™ 80 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 SAFETY Safety Standards Booklet Index 17. CGA booklet TB-3, Hose Line Flashback Arrestors, obtainable from 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 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 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 is a constant current, continuous control plasma of a product or structure is the responsibility of the user. Variation cutting power source.

  • Page 11: Installation

    FLEXCUT™ 80 INSTALLATION TECHNICAL SPECIFICATIONS - K4809-1 FLEXCUT™ 80 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 80% Duty Cycle 70 Amps...

  • Page 12: Select Suitable Location

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

  • Page 13: Input Plug Installation

    Only a qualified electrician should connect the input leads to the FLEXCUT 80. Connections should be made in accordance with all local and national electrical codes and The FLEXCUT™ 80 contains a built-in filter but depending on the the connection diagrams.

  • Page 14: Connecting The Gas Supply

    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. FlexCut 80 Cut and gouge CapaCities MAXIMUM OUTPUT CURRENT Mechanized Cut Capacity - Material Thickness Recommended cut capacity at 24 ipm 3/4 in.

  • Page 15: Operation

    FLEXCUT™ 80 OPERATION GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL OPERATION 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 OPERATION 4. Thermal yellow LED: CONTROLS AND SETTINGS The machine is overheated and the output has been disabled. This usually occurs when the FIGURE B.2 FLEXCUT™ 80 front command panel. duty cycle of the machine has been exceeded. Leave the machine ON to allow the internal components to cool.
  • Page 17 FLEXCUT™ 80 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

    KP4141-14 (40A) KP4141-17 KP4141-15 (80A) Gouging Setup: Shielded Contact Gouging The FLEXCUT 80 is designed for Shielded contact. A special If gouging metal and not cutting Electrode Electrode insulated nozzle is used in completely through the part is required, a...

  • Page 19: Hand Cutting Charts

    FLEXCUT™ 80 OPERATION Hand Cutting Process • Pierce the work piece by slowly lowering the torch onto the metal 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 TOMAHAWK 1500 OPERATION Mild steel Cut CHarts - FlexCut 80; lC105 Hand torCH < + > ' # # # # # # # # # # # # # # # " ) C " / < %#!" " ! ' &...
  • Page 21 TOMAHAWK 1500 OPERATION stainless steel Cut CHarts - FlexCut 80; lC105 Hand torCH & # 3 " ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) = < > 5 & 3 " "...
  • Page 22 TOMAHAWK 1500 OPERATION aluMinuM Cut CHarts - FlexCut 80; lC105 Hand torCH & # 8 " ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) = <...

  • Page 23: Gouging Process

    FLEXCUT™ 80 OPERATION Gouging Process Gouging is a process used to remove material without cutting entirely WARNING through the workpiece. The FLEXCUT™ 80 has the capability of performing plasma gouging with the proper consumables attached to ELECTRIC SHOCK CAN KILL. the torch.

  • Page 24: Mechanized Cutting

    FLEXCUT™ 80 OPERATION Removing the Torch Consumables Mechanized Torch Installation MECHANIZED CUTTING To remove the torch consumables, perform the following steps: It is recommended that the FLEXCUT™ 80 mechanized torch be installed on a positioner with an arc voltage control capable of 1.

  • Page 25: Machine Interface

    FLEXCUT™ 80 OPERATION Making a Cut Machine Interface Setting up a Cut The FLEXCUT™ 80 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 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 OPERATION 40 aMp MeCHanized sHield ConsuMables SHIELD SWIRL RING LC105M TORCH RETAINING CAP NOZZLE ELECTRODE BK12849-13 BODY BK12849-10 BK12849-4 BK12849-9 BK12849-1 '5('# 0 * , <+ 45'//2 '5('#=', >) >#=', >) A& >/ >/ #D,.:) @.>' -.)/ -.)/ 9:*5 !"...
  • Page 28 FLEXCUT™ 80 OPERATION 60 aMp MeCHanized sHield ConsuMables SHIELD RETAINING CAP SWIRL RING ELECTRODE LC105M TORCH NOZZLE BK12849-2 BK12849-9 BK12849-1 BODY BK12849-10 BK12849-5 '8('# 0 * , <+ 78'//2 '8('#=', >) >#=', >) @& >/ >/ #C,.6) D.>' -.)/ -.)/ 56*8 !"...
  • Page 29 FLEXCUT™ 80 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 '8('# 0 * , <+ 78'//2 '8('#=', >) >#=', >) @& >/ >/ #C,.6) D.>' -.)/ -.)/ 56*8 !"...

  • Page 30: Consumable Life

    FLEXCUT™ 80 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. The FLEXCUT™ 80 utilizes the latest advancement in technology thorough understanding of the cutting characteristics of the for extending the life of the torch consumable parts.
  • Page 31 FLEXCUT™ 80 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 CENTER HOLE OUT OF ROUND...
  • Page 32 FLEXCUT™ 80 OPERATION Suggestions for Extra Utility from the FLEXCUT™ 80 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. Occasionally an oxide layer may form over the tip of the electrode, creating an insulating barrier between the electrode and nozzle.

  • Page 33: Options/Accessories

    FLEXCUT™ 80 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) K2849-2 LC105 Handheld Plasma Torch 50' (15m) K2849-3 LC105M Mechanized Plasma Torch 25' (7.5m)

  • Page 34: Maintenance

    FLEXCUT™ 80 MAINTENANCE MAINTENANCE POWER SUPPLY MONTHLY PROCEDURES 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 35: 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 36 FLEXCUT™ 80 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 37 FLEXCUT™ 80 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENTS COURSE OF ACTION The FLEXCUT™ 80 powers up properly but 1. Turn the output knob to purge zone on there is no response when the trigger is the front of the FLEXCUT™...
  • Page 38 FLEXCUT™ 80 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 39 FLEXCUT™ 80 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. 2.
  • Page 40 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 41 FLEXCUT™ 80 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. If the pilot arc does not start, the machine automati- cally will enter into a safe status condition that will allow troubleshooting as necessary.
  • Page 42 FLEXCUT™ 80 DIAGRAMS...
  • Page 43 FLEXCUT™ 80 DIAGRAMS...
  • Page 44 FlexCut 80 - 12589...
  • Page 45 THIS PAGE INTENTIONALLY LEFT BLANK...
  • Page 46 Index of Sub Assemblies - 12589 PART NUMBER DESCRIPTION P-1022-A INDEX OF SUB ASSEMBLIES P-1022-B.2 MISCELLANEOUS ITEMS P-1022-C CASE FRONT ASSEMBLY P-1022-D UPPER SHELF ASSEMBLY P-1022-E BASE ASSMEBLY P-1022-F HEATSINK ASSEMBLIES P-1022-G CASE BACK & WRAPAROUND ASSEMBLY FlexCut 80 - 12589...
  • Page 47 Index of Sub Assemblies - 12589 P-1022-A.jpg FlexCut 80 - 12589...
  • Page 48 PLUG & LEAD ASBLY P6 TO P1 & P66 K2849-1 LC105 HANDHELD PLASMA TORCH 25' (7.5m) K2849-2 LC105 HANDHELD PLASMA TORCH 50' (15m) K2849-3 LC105M MACHINE PLASMA TORCH 25' (7.5m) K2849-4 LC105M MACHINE PLASMA TORCH 50' 9SM25351 GROUND CLAMP ASSEMBLY FlexCut 80 - 12589...
  • Page 49 Miscellaneous Items No Image FlexCut 80 - 12589...
  • Page 50 ADAPTER M12 TO 1/4 NPT 9SS30229-2 PUSH IN FITTING 9SS28188-23 KNOB 9SM25206 PLUG AND LEAD ASBLY CNC CONNECTOR 9SS8025-96 SELF TAPPING SCREW 9SS17062-11 CABLE CONNECTOR CAP 9ST13086-233 DECAL WARNING 9SM24770 HANDLE 9SS9225-100 SELF TAPPING SCREW 9SS9262-184 WASHER FlexCut 80 - 12589...
  • Page 51 Case Front Assembly P-1022-C.jpg FlexCut 80 - 12589...
  • Page 52 9SS8025-76 SELF TAPPING SCREW 9SS9225-99 SELF TAPPING SCREW 9SS13490-249 CAPACITOR 9SS22745-6 CAPACITOR INSULATION 9SS29506 CAPACITOR BRACKET 9SS9225-99 SELF TAPPING SCREW 9SS9262-98 PLAIN WASHER 9SE106A-2 LOCKWASHER 9SCF000198 1/4-28HN 9SS29965-1 METRIC SEMS SCREW 9SG7900-1 INPUT CONTROL BOARD ASSEMBLY FlexCut 80 - 12589...
  • Page 53 Upper Shelf Assembly PART NUMBER DESCRIPTION 9ST9447-87 SOCKET HEAD CAP SCREW #6-32X.50 9SE106A-13 LOCKWASHER 9SS9262-181 PLAIN WASHER 9ST10642-360 FLEX TUBE 9ST10642-361 FLEX TUBE 9ST10642-385 FLEX TUBE 9ST10642-362 FLEX TUBE 9ST10642-363 FLEX TUBE FlexCut 80 - 12589...
  • Page 54 Upper Shelf Assembly P-1022-D.jpg FlexCut 80 - 12589...

  • Page 55: Base Assembly

    9SM25008-1 FAN BAFFLE 9SS9225-99 SELF TAPPING SCREW 9SS9225-99 SELF TAPPING SCREW 9SG7875 TRANSFORMER ASSEMBLY 9SS9225-68 THREAD FORMING SCREW (CUTTING) 9SG8127 CHOKE ASSEMBLY 9SS9225-68 THREAD FORMING SCREW (CUTTING) 9SS29507 CORNER CAP 9SS9225-100 SELF TAPPING SCREW 9SS9262-184 WASHER FlexCut 80 - 12589...
  • Page 56 Base Assembly P-1022-E.jpg FlexCut 80 - 12589...
  • Page 57 RECTIFIER PC BOARD ASSEMBLY 9SS29965-3 METRIC SEMS SCREW 9SS30440 PLUG & LEAD ASBLY 9SL16608 HEATSINK AND PC BD ASSEMBLY 9SL16607-2 HEATSINK 9SM24769-2 ISOTOP PARALLEL DIODES 9ST9447-87 SOCKET HEAD CAP SCREW #6-32X.50 9SS9262-181 PLAIN WASHER 9SE106A-13 LOCKWASHER FlexCut 80 - 12589...
  • Page 58 9SS9262-181 PLAIN WASHER 9SE106A-13 LOCKWASHER 9SG7890-1 OUTPUT PC BD ASBLY 9SS29965-1 METRIC SEMS SCREW 9SM24912-5 SOT-227B HEAT SINK MOUNT POWER RESISTOR 9ST9447-87 SOCKET HEAD CAP SCREW #6-32X.50 9SS9262-181 PLAIN WASHER 9SE106A-13 LOCKWASHER 9SS29965-1 METRIC SEMS SCREW FlexCut 80 - 12589...
  • Page 59 Heatsink Assemblies P-1022-F.jpg FlexCut 80 - 12589...

  • Page 60: Wiring Diagram

    DECAL GREEN INITIATIVE 9SS19720-1 PLASMA WARNING DECAL (ENGLISH) 9SS19720-1F PLASMA WARNING DECAL FRENCH 9SS19720-1S PLASMA WARNING DECAL SPANISH 9ST13260-4 DECAL-EARTH GROUND CONN 9SS31405 ELECTRIC SHOCK WARNING DECAL 9SG8031 WIRING DIAGRAM 9SM24770 HANDLE 9SS9225-100 SELF TAPPING SCREW 9SS9262-184 WASHER FlexCut 80 - 12589...
  • Page 61 Case Back & Wraparound Assembly P-1022-G.jpg FlexCut 80 - 12589...
  • Page 62 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 63 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 64 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.

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