Lincoln Electric FlexCut 125 Operator's Manual
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Lincoln Electric FlexCut 125 Operator's Manual

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Operator's Manual
FlexCut
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Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM10300-A
| Issue D ate Nov-16
© Lincoln Global, Inc. All Rights Reserved.
25
™
For use with machines having Code Numbers:
12478

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Summary of Contents for Lincoln Electric FlexCut 125

  • Page 1 Operator’s Manual FlexCut ™ For use with machines having Code Numbers: 12478 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) IM10300-A | Issue D ate Nov-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: Electric Shock Can Kill

    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™ 125 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™ 125 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™ 125 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™ 125 TABLE OF CONTENTS Safety General Description...........................10 Preheat Temperature For Plasma Cutting ..................10 Duty Cycle............................10 User Responsibility..........................10 Design Features And Advantages ......................10 Installation ..........................Section A Select Suitable Location........................A-2 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™ 125 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™ 125 is a constant current, continuous control plasma of a product or structure is the responsibility of the user. Variation cutting power source.

  • Page 11: Technical Specifications

    FLEXCUT™ 125 INSTALLATION TECHNICAL SPECIFICATIONS - K4160-1 FLEXCUT™ 125 RATED OUTPUT AT 40° C RECOMMENDED INPUT WIRE Duty Cycle CURRENT VOLTAGE For all plasma cutting applications 100% 125A 175 VDC Based on U.S. National Electrical Code Ambient Temperature 30 C or Less OUTPUT STO, 600V Current Range Open Circuit Voltage Pilot Current...

  • Page 12: Installation

    WARNING STACKING The FLEXCUT 125 ON/OFF switch is not intended as a The FLEXCUT™ 125 cannot be stacked. service disconnect for this equipment. Only a qualified electrician should connect the input leads to the FLEXCUT 125.

  • Page 13: Input Plug Installation

    FLEXCUT™ 125 INSTALLATION INPUT PLUG INSTALLATION WARNING A 10 ft.(3m) power cord is provided with the FLEXCUT 125. The FLEXCUT 125 ON/OFF switch is not intended as a service disconnect for this Three Phase Input Only equipment. Only a qualified electrician should connect the input leads to the FLEXCUT 125.

  • Page 14: Input Voltage Selection

    FLEXCUT™ 125 INSTALLATION INPUT VOLTAGE SELECTION The Flexcut™ 125 is shipped connected for 460 VAC input. To reconfigure the machine for a different input voltage see the panel on the rear of the unit (Figure A.2). With input power removed from the machine, move the Auxiliary (“A”) lead from the 460V tap to the desired input voltage.

  • Page 15: Operation

    FLEXCUT™ 125 OPERATION GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL OPERATION SAFETY PRECAUTIONS WARNING OR CAUTION WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts GAS PURGE or electrode with skin or wet clothing.

  • Page 16: Controls And Settings

    FLEXCUT™ 125 OPERATION CONTROLS AND SETTINGS FIGURE B.2 - Front Panel FIGURE B.3 - Back Panel 1. LCD Display: Shows available modes and real time parame- 9. Input Cord Strain Relief: Used to connect the unit to input ters. power. 2.

  • Page 17: User Interface

    FLEXCUT™ 125 OPERATION USER INTERFACE Active Mode Screen - See Figure B.4 Mode Select Screen FIGURE B.4 Cutting Output Current Active Mode Icon Output Gas Pressure 25ft Torch Length Press to Select Active Mode Icon – The currently selected mode icon will be displayed here.
  • Page 18 FLEXCUT™ 125 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 Torch Size Reset Factory Settings – Use to Torch Size –...

  • Page 19: Mechanized Cutting

    FLEXCUT™ 125 OPERATION Removing the Torch Consumables Mechanized Torch Installation MECHANIZED CUTTING WARNING It is recommended that the FLEXCUT™ 125 mechanized torch be installed on a positioner with an arc voltage control capable of Turn off the machine prior to removing maintaining the cutting arc voltage within 1 volt.

  • Page 20: Machine Interface

    FLEXCUT™ 125 OPERATION Making a Cut Machine Interface Setting up a Cut The FLEXCUT™ 125 comes standard with a machine interface. Interface signals provided include: Arc Start, Arc Initiated, Use the following procedure to make a cut with the Arc Voltage (raw or divided) and Force Mark. These signals are FLEXCUT™...
  • Page 21 FLEXCUT™ 125 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 22 FLEXCUT™ 125 OPERATION !"#$%&#%'()*+,-'.#/),'0.#(1+/2%*30'/ Shield Retaining Cap Nozzle Swirl Ring Electrode LC125M Torch Body BK14300-3 BK14300-15 BK14300-7 BK14300-13 BK14300-1 4,0.#56''0 7,'8('# 4*6'8,*0#?),(;+'// 78'//28' 7,'8('#>',<)6 =266,+<#>',<)6 E&6,%2%#5'66,+</ 781.2(6,1+#5'66,+</ B'8C#D,.6) 9'0*: +,&- +,&- "#$ #%& ./0123% ./0123% 45-32 67689 8;< 676<: 6766 44-32 676;6 <56...
  • Page 23 FLEXCUT™ 125 OPERATION !"#$%&#%'()*+,-'.#/),'0.#(1+/2%*30'/ Shield Retaining Cap Nozzle Swirl Ring Electrode LC125M Torch Body BK14300-3 BK14300-15 BK14300-8 BK14300-13 BK14300-1 4,0.#56''0 7,'8('# 4*6'8,*0#D),(;+'// 78'//28' 7,'8('#C',<)6 =266,+<#C',<)6 E&6,%2%#5'66,+</ 781.2(6,1+#5'66,+</ >'8?#@,.6) A.<'# 9'0*: +,&- +,&- 56*86 "#$ #%& ./0123% ./0123% 45-32 67656 6746 9<8 67656 46-32...
  • Page 24 FLEXCUT™ 125 OPERATION !"#$%&#%'()*+,-'.#/),'0.#(1+/2%*30'/ Shield Retaining Cap Nozzle Swirl Ring Electrode LC125M Torch Body BK14300-4 BK14300-15 BK14300-9 BK14300-13 BK14300-1 4,0.#56''0 7,'8('# 4*6'8,*0#A),(;+'// 78'//28' 7,'8('#@',<)6 =266,+<#@',<)6 F&6,%2%#5'66,+</ 781.2(6,1+#5'66,+</ C'8D#E,.6) >.<'# 9'0*: +,&- +,&- 56*86 "#$ #%& ./0123% ./0123% 56478 5655 47< 56585 46:= 7>4;...
  • Page 25 FLEXCUT™ 125 OPERATION # " %& & & Shield Retaining Cap Nozzle Swirl Ring Electrode LC125M Torch Body BK14300-4 BK14300-15 BK14300-10 BK14300-13 BK14300-1 5-1/$67((1 8-(9)($ 5+7(9-+1$B*-)<,(00 89(0039( 8-(9)($A(-=*7 >377-,=$A(-=*7 D'7-&3&$6(77-,=0 892/3)7-2,$6(77-,=0 E(9F$G-/7* ?/=($ :(1+; +,&- +,&- 67+97 "#$ #%& ./0123% ./0123% 789:7 7867...
  • Page 26 FLEXCUT™ 125 OPERATION C " ( " > + Shield Retaining Cap Nozzle Swirl Ring Electrode !"#$%&'$&()*+,-.(/$0*-(1/$)2,03&+41(0 LC125M Torch Body BK14300-4 BK14300-15 BK14300-11 BK14300-13 BK14300-1 5-1/$67((1 8-(9)($ 5+7(9-+1$@*-)<,(00 89(0039( 8-(9)($C(-=*7 >377-,=$C(-=*7 G'7-&3&$6(77-,=0 892/3)7-2,$6(77-,=0 D(9E$F-/7* ?/=($ :(1+; +,&- +,&- 67+97 "#$ #%&...

  • Page 27: Consumable Life

    FLEXCUT™ 125 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™ 125 utilizes the latest advancement in thorough understanding of the cutting characteristics of the technology for extending the life of the torch consumable parts.

  • Page 28: Inspection Of Consumable Parts

    FLEXCUT™ 125 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 debris and clean as necessary. !"#$ %&'!()$*+,# ),##()$%-(*")$%,&...

  • Page 29: Suggestions For Extra Utility From The Flexcut™ 125 System

    FLEXCUT™ 125 OPERATION SUGGESTIONS FOR EXTRA UTILITY FROM THE FLEXCUT™ 125 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. 1. Occasionally an oxide layer may form over the tip of the electrode, creating an insulating barrier between the electrode and nozzle.

  • Page 30: Accessing Divided Arc Voltage

    FLEXCUT™ 125 OPERATION ACCESSING DIVIDED ARC VOLTAGE The Flexcut™ 125 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: The machine is configurable to provide a divided voltage of 20:1, 30:1, 40:1, or 50:1 instead of raw arc voltage by following these steps:...

  • Page 31: Options/Accessories

    FLEXCUT™ 125 ACCESSORIES OPTIONS/ACCESSORIES The following options/accessories are available for your FlexCut™ Plasma cutter from your local Lincoln Distributor. TORCHES The following replacement or optional torches are available: K4300-4 LC125 Mechanized Torch 25' (7.5m) K4300-5 LC125 Mechanized Torch 50' (15m) K4300-6 LC125 Mechanized Torch 75' (22.5m) K4302-2...

  • Page 32: Maintenance

    FLEXCUT™ 125 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 33: 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 34 FLEXCUT™ 125 TROUBLESHOOTING Possible Cause 0298 Gas input line is disconnected or input pressure is too low. Recommended Course of Action Check that the gas line feeding the machine is properly connected and that the pressure is above 90 psi for cutting or above 50 psi for marking or gouging. DESCRIPTION: Low Gas Pressure Possible Cause...
  • Page 35 FLEXCUT™ 125 TROUBLESHOOTING Possible Cause 0021 Pilot Stuck Open Recommended Course of Action Nozzle could be missing or debris could be stuck between the torch consumables. Remove and replace the consumables, checking for proper DESCRIPTION: installation. Open Pilot - Check Consumables Possible Cause Pilot Stuck Closed 0021...
  • Page 36 FLEXCUT™ 125 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE CAUSE RECOMMENDED (SYMPTOMS) COURSE OF ACTION Input circuit breaker trips repeatedly. 1. Verify that the input circuit protection is properly sized per the voltage being sup- plied. See Technical Specification page. 2.
  • Page 37 FLEXCUT™ 125 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE CAUSE RECOMMENDED (SYMPTOMS) COURSE OF ACTION The FLEXCUT™ 125 powers up properly 1. Press the purge button on the front of the but there is no response when output is FLEXCUT™...
  • Page 38 FLEXCUT™ 125 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE CAUSE RECOMMENDED (SYMPTOMS) 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™ 125 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE CAUSE RECOMMENDED (SYMPTOMS) COURSE OF ACTION Pilot arc starts but will not transfer when 1. Check work lead connection for clean, brought near work. secure connection. 2. Plasma will only cut conductive material. Do not attempt to cut fiberglass, plastic, rubber, PVC or any other non-conduc- tive material.

  • Page 40: Diagrams

    FLEXCUT™ 125 DIAGRAMS FRONT OF MACHINE J23-1 J23-2 J4-1 J23-3 J4-2 J23-4 J4-3 J4-4 J24-1 J4-5 J24-2 J4-6 J24-3 J4-7 J24-4 J4-8 J22-1 J22-1 J22-2 J22-2 J22-3 J22-3 J22-4 J22-4 J22-5 J22-5 J1-1 J22-6 J22-6 J1-2 J1-3 J1-4 J1-5 J28-1 J1-6 J28-2 J1-7...
  • Page 41 FLEXCUT™ 125 DIAGRAMS...
  • Page 42 FLEXCUT™ 125 DIAGRAMS 1.750 15.12 13.760 4.710 2.650 2.529 1.480 ALL DIMENSIONS ARE IN INCHES...
  • Page 43 Flexcut 125 - 12478...
  • Page 44 Index of Sub Assemblies - 12478 PART NUMBER DESCRIPTION P-898-A INDEX OF SUB ASSEMBLIES P-898-B.2 MISCELLANEOUS ITEMS P-898-C CASE FRONT ASSEMBLY P-898-D UPPER SHELF ASSEMBLY P-898-E BASE ASSEMBLY P-898-F HEATSINK ASSEMBLIES P-898-G CASE BACK ASSEMBLY P-898-H ROOF & SIDES Flexcut 125 - 12478...
  • Page 45 Index of Sub Assemblies - 12478 P-898-A.jpg Flexcut 125 - 12478...
  • Page 46 Miscellaneous Items PART NUMBER DESCRIPTION 9SM25672 PLUG AND LEAD ASBLY 9SS18250-1091 PLUG AND LEAD ASBLY 9SS18250-1092 PLUG AND LEAD ASBLY 9SS18250-1095 PLUG AND LEAD ASBLY 9SM25351-1 GROUND CLAMP ASSEMBLY Flexcut 125 - 12478...
  • Page 47 Miscellaneous Items No Image Flexcut 125 - 12478...
  • Page 48 POWER SWITCH ASSEMBLY 9SS29541 MAIN POWER SWITCH 9SM25210-1 TORCH CONNECTOR ASBLY 9SS22990-2A BULKHEAD NUT 9SS30904 KEYING PIN 9SS29508 TWIST MATE RECEPTACLE 9SS9262-2 PLAIN WASHER 9ST13086-233 WARNING DECAL 9SS30683 ADAPTER M12 TO 1/4 NPT 9SS30229-2 PUSH IN FITTING Flexcut 125 - 12478...
  • Page 49 Case Front Assembly P-898-C.jpg Flexcut 125 - 12478...
  • Page 50 9ST13260-4 DECAL-EARTH GROUND CONN 9SM22062-4 INPUT RECTIFIER ASSEMBLY 9SM15454-18 INPUT RECTIFIER MODULE 9SS9262-3 PLAIN WASHER 9SE106A-1 LOCKWASHER 9SS25930-5 TORX BUTTON HEAD SCREW #10-24X.62 9SS24574-3 HEATSINK 9ST13637-6 DIODE-BRIDGE35A400VF-W1-PH 9SS9262-3 PLAIN WASHER 9SE106A-1 LOCKWASHER 9SCF000010 #10-24HN 9ST14605 INSULATOR Flexcut 125 - 12478...
  • Page 51 PLAIN WASHER 9SE106A-2 LOCKWASHER 9SS18491-1 MOV ASBLY 9ST10642-397 FLEX TUBE 9ST10642-400 FLEX TUBE 9ST10642-399 FLEX TUBE 9SS30229-9 PUSH-IN FITTING WYE 3/8 TUBE 9SS13000-129 AUXILIARY TRANSFORMER 9SS9262-98 PLAIN WASHER 9SS9225-32 THREAD FORMING SCREWS 9SS30229-12 PUSH-IN FITTING BRANCH TEE Flexcut 125 - 12478...
  • Page 52 Upper Shelf Assembly P-898-D.jpg Flexcut 125 - 12478...

  • Page 53: Base Assembly

    9SG8552 TRANSFORMER ASBLY 9SS9225-68 THREAD FORMING SCREW (CUTTING) 9SG8580 SWITCHBOARD ASSEMBLY 9SS9225-68 THREAD FORMING SCREW (CUTTING) 9SL16608-1 OUTPUT BD & HEATSINK ASSEMBLY 9SS9225-68 THREAD FORMING SCREW (CUTTING) 9SL16922 OUTPUT CHOKE ASBLY 9SS9225-68 THREAD FORMING SCREW (CUTTING) Flexcut 125 - 12478...
  • Page 54 Base Assembly P-898-E.jpg Flexcut 125 - 12478...
  • Page 55 SELF TAPPING SCREW 9SG8580 SWITCHBOARD ASSEMBLY 9SM24992 HEATSINK 9SM24993 HEATSINK BRACKET 9SCF000069 1/4-20X1.25HHCS 9SS9262-98 PLAIN WASHER 9SE106A-2 LOCKWASHER 9ST14605 INSULATOR 9ST11267-B INSULATOR 9SS31808 INSULATION 9SS31654-1 SWITCH BOARD ASBLY 9SS25930-6 TORX BUTTON HEAD SCREW 1/4-20X.62 9SE106A-2 LOCKWASHER Flexcut 125 - 12478...
  • Page 56 Heatsink Assemblies P-898-F.jpg Flexcut 125 - 12478...
  • Page 57 #10-24HN 9SE106A-1 LOCKWASHER 9SCF000010 #10-24HN 9SS31656 RATING PLATE 9SM25739 VOLTAGE DIVIDER BRACKET 9SS31412-1 VOLTAGE DIVIDER PC BD ASBLY 9ST9187-13 #10-24HLN-1817/1-NYLON INSERT 9ST11248 BRASS TUBE FITTING 9SS23044 PNEUMATIC NIPPLE-1/4NPT 9SS9262-36 PLAIN WASHER 9SS9225-68 THREAD FORMING SCREW (CUTTING) Flexcut 125 - 12478...
  • Page 58 Case Back Assembly PART NUMBER DESCRIPTION 9SS9225-66 SELF TAPPING SCREW 9SM25530 RECONNECT COVER 9ST13259-2 GROUNDING DECAL 9SS9225-68 THREAD FORMING SCREW (CUTTING) 9SS31805 REGULATOR LOCK 9SS31806 FACTORY CALIBRATED DECAL Flexcut 125 - 12478...
  • Page 59 Case Back Assembly P-898-G.jpg Flexcut 125 - 12478...

  • Page 60: Wiring Diagram

    SPEED GRIP NUT RETAINER 9SS9225-68 THREAD FORMING SCREW (CUTTING) 9SM25674 LEFT CASE SIDE ASSEMBLY 9SL16921 LEFT CASE SIDE 9SM25585-1 DECAL 9SS27368-4 DECAL LE LOGO 9SS28039-2 DECAL GREEN INITIATIVE 9ST10097-5 SPEED GRIP NUT RETAINER 9SS9225-68 THREAD FORMING SCREW (CUTTING) Flexcut 125 - 12478...
  • Page 61 Roof & Sides P-898-H.jpg Flexcut 125 - 12478...
  • Page 62 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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